Beruflich Dokumente
Kultur Dokumente
Rev. : B
Page : 1/103
OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
1. SYSTEM DESIGN
1.1. PURPOSE
Gas Turbine need starting equipment to accelerate from standstill and follow a preset
speed-time profile as required by the ignition and start-up procedure. Once the Gas
Turbine can deliver enough torque, further acceleration up to the synchronous speed is
accomplished by the turbine itself and the starting equipment is no more necessary.
The Synchronous Generator, fed by a suitable variable-voltage / variable-frequency power
source, can be used as a variable speed electric motor to start the Gas Turbine.
The variable-frequency power source is usually a thyristor converter: a static equipment
that, fed from the network, can supply the Synchronous Machine with finely controlled
voltage and frequency, so that the aforesaid speed-time profile can be accured followed.
The converter equipment, known as Load Commutated Inverter ( LCI ), has gained wide
acceptance also in pumping storage stations and as industrial drive, due to its ability to
reach high power and/or high speed levels, and because of the robustness of the LCI.
The simplified schematic diagram of the drive system is shown on Fig. 1. It shows the
overall system including the Gas-Turbine (GT), the Starter Equipment, the Filed Exciter
(SE) .
At start-up the Generator is disconnected from the medium voltage (m.v.) Main Bus and is
supplied by the Starter Equipment that takes the power from the m.v. Auxiliary Bus
through the converter transformer ST.
L
D.C. LINK
K’ K” MS GT
ST
SN
SE
FIG.1.1
The Field Exciter regulates the Generator flux as required by the voltage rating limits of
the power converter, as recalled in the next paragraph.
When producing power the generator is connected to the main Bus and the Starter C.B. is
open. The Field Exciter regulates the generator flux to comply with the active and reactive
power requirements of the power station.
More details of the Starter Equipment include :
a ) current and voltage transformer that are used to acquire the converter input and
output current and voltage values as well as the value of the generator field current.
b) the Control equipment that is the Digital Control Module ( with the Converter
Interface and the PLC interface ).
c) the PLC that implements the drive logic and connects field signals
1.2.1 Medium voltage dry type cast resin step down transformer
The three phase type transformer shall be installed between a M.V. three-phase supply
line and a static converter . The transformer shall supply a rectifier bridge - six pulse, total
controlled, thyristor based Graetz bridge operating at fixed frequency
When the transformer is fitted up with a hausing there is no need to keep the insulation
distance while it is already kept between the transformer and the housing.
In the installation cabin it is necessary to perform openings for air inlet on the same level
of the floor for receiving the fresh air and to perform openings on the apposite side on
the upper side near the roof for outlet of the warm air.
During the operations of connections and installation of the transformer it is possible that
some tools, bolts and or washers have been inserted accidentally in the cooling ducts of
the windings or left on the transformer. Since it is necessary to clean up the transformer
accurately so that once the transformer is under voltage does not happen failures due to
the presence of strange objects
Metal enclosed switchboard for indoor installation are made of standardized units employed
in the transformer cabins, to control and protect lines, transformers, motors and capacitors,
and usually in the M.V. electrical distribution.
Metal enclosed switchboards are constructed in standard and internal arc versions (in
compliance with IEC 298 Equipment AA ).
Legend
6
5
Aux. contacts box
4 Sf6 off-load switch
and earth switch
Operating mechanism
for open/close Sf6 off-load
switch and earth switch
Incoming line
M.V. circuit breaker
Inspection windows
1.2.2.2 Compartments
Bus-Bar Cubicle
The bus-bars are realised in copper flat bar and fixed to the terminals of the line
disconnecting switch or switch-disconnector, according to the type of compartment in
question; the bus-bars pass from one compartment to another directly, without the use
of baffle plates, forming a continuous duct.
Access to the feeder circuit-breaker cubicle is provided through the door on the front of
the compartment. ( See Fig. 1.2.2.2-1 , 1.2.2.2-2)
The cubicle houses an ABB SACE HAD SF6 circuit-breaker in fixed or plug-in versions
fitted if necessary with on board current transformer, a line disconnecting switch, an earth
switch and the terminals for connection of the Medium Voltage cables.
The cubicle may also contain the following components:
- current transformer (in addition or as an alternative to those already installed on
board)
- voltage transformers
- capacitive voltage dividers
The window on the door of the cubicle makes it possible to inspect and check the position
of the disconnecting switches.
250
2250
1150 1400
Instrument Cubicle
The instrument cubicle is mounted in the auxiliary circuit drawer, above the feeder circuit-
breaker cubicle and in front of the bus-bar cubicle.
This cubicle contains all the low voltage equipment generally used, in particular the
following.
- terminal boards, raceways and cables for connection of the auxiliary circuits of the
cubicle and the other compartments of the switchboard
- auxiliary accessories of the circuit-breaker and cubicle ( metering instruments,
protection relays, control and signalling devices, fuses, protection circuit-breakers of
the auxiliary relays etc. )
The circuit breakers used in Switchboards are ABB SACE SF6 series HD4R circuit
breakers suitable for up to 1250 A at 24 kV (see figure 1.2.2.3).
They are ideal for the protection and control of transformers and distribution lines as well
as for motor control and protection.
The circuit breaker is supplied in fixed version.
The HD4/... circuit-breakers are constructed using the separate pole technique. They are
insulated in sulphur hexafluoride, for indoor installation, and are pressure systems sealed
for operating life (IEC 60056 and CEI 17-1 Standards).
In addition to the accessories supplied, the circuit breaker may also be fitted
with a key lock (open or closed position).
The three poles, the operating mechanism and any optional accessories are mounted on
a sturdy support frame.
Protection is guaranteed by the current transformers installed on the circuit breaker
together with the ABB SACE electronic release switches PR521.
1 closing pushbutton
2 opening pushbutton
These are two appliances in a single stainless steel parallelepiped hermetically welded
casing filled with SF6 at very low pressure to extinguish the electric arc and to insulate the
live components (between the phases and to earth) of the equipment housed in the
enclosure (see fig.1.2.2.4).
Epoxy resin bushings positioned on the upper and bottom surfaces ensure the electric
connection of the internal equipment consisting of a three-pole switch-disconnector and a
three-pole earthing switch with making capacity.
The operations of the two appliances is carried out by a special operating mechanism
(independent from the operator) installed on the front of the enclosure that permits placing
the internal equipment on the three positions shown by fig. 1.2.2.4a as follows:
Line close – Earth open;
Earth and line open;
Earth closed – line open
1.2.2.5 Earth
All the steel structural parts are connected together by means of special nuts and screws
designed to guarantee efficient electrical contact between the parts.
The doors are connected to earth by means of flexible copper strands having an
appropriate cross-section.
A 30 x 5 mm copper bus-bar connects the entire switchboard longitudinally to earth the
switchboard; the earth connections of the main equipment (disconnecting switch, line
disconnecting switch, current transformers, voltage transformers etc.) are branched on
each compartment.
The static starter consist of 3 separated compartment ( See Fig.1.2.3 ) that contain:
a) POWER COMPARTMENT
+.11 +.12
DC LINK CONVERTER
2300
1200
2000 1000
a) Power Compartment
U V W
=H01.LL01
L1 L2 L3
[front view]
[side view]
[front view]
FRONT REAR
The reactor has the function to limit current waviness in the intermediate continuous
current circuit, it is usually made of an air cooled iron core. It is located in compartment
Nr. +11
( See fig.1.2.3f ).
It is equipped with a maximum temperature sensor.
=G3.D01 –XV01
=G3.D01 –XV01
=G3.L04 –BP01 =G3.L04 –BP01
=G1.H01 –LL01
=G1.J01 –QT01
=G1.H01 –LL01
=G3.Y01 –EH02
1000
Compartment +21 contains all circuits and equipment completing the drive.
They consist of:
b.1) Control panel
b.2) Interface cards and transducers
b.3) PLC and relay circuits interfaced with it
The power supplies of these equipments derive, according to the Client availabilities, from:
Commonly referred to as control rack, it contains all control electronic cards, and, on the
side door, the local commands. See figure.
Control cards
for inverter
bridge, rectifier
bridge
and speed
Frame 1
In this frame are assembled all power supplies necessary to generate the various power
supply voltages for the electronic cards.
Frame 2
This frame contains the cards that constitute the control; these cards are Europe 2 standard
size. They can present customizable components varying according to the application. For
this reason the values of these calibrations are reported in the customization sheets of the
project functional diagrams.
. NOTE Before replacing a card, check that all components that can be
calibrated match the system ones.
Frame 3
This frame contains the redundant cards that constitute the control; these cards are Europe
2 standard size. They can present customizable components varying according to the
application. For this reason the values of these calibrations are reported in the
customization sheets of the project functional diagrams
The following table shows a brief description of the cards available on the control.
There are a series of analogics instruments for the visualization of the principal greatness
Field Current Indicator =G3.U01 - PA01
Converter Input Voltage Indicator (Delta group) =G3.U01 - PV01
Indicator Of The Dc Current Converter =G3.U01 - PA02
Generator Voltage Indicator =G3.U01 - PV02
Set Speed Indicator =G3.U01 - PF01
and a
Operator Panel =G3.N01 – HS01
Temperature transformer monitoring unit =G3.R01 – TH01
The-HS01 text viewer is directly connected to the PLC CPU where all drive alarms and
states can be read (see chapter 1.5.8 for the message list).
Temperature
Programmable text monitoring unit
viewer
HS01 -TH01
Reset Selector
Pushbutton Switch
-SB01 -SB03
Emergency
Pushbutton
-SB02
The function of the interface cards is that of connecting and adapting all signals coming
from the transducers located in the power compartments and from outside the panel.
All these cards are 24Vdc supplied and are divided as follows:
Cards for digital signals
Cards for analog signals
The cards can present customizable components varying according to the system. For this
reason the values of these calibrations are reported in the customization sheets of the
project functional diagrams.
. NOTE Before replacing a card, check that all components that can be
calibrated match the system ones.
Even if the transducers are not located inside the auxiliary compartment, due to their
connection with the interface cards, they will be described in this section.
Cards for digital signals
This group includes those cards managing the digital signals from and to the control. The
connection of these cards is accomplished through a multi polar cable with a 37 pin
connector, while towards the field it is obtained by means of a screw terminal board.
The following table shows a brief description of the digital cards
The input of the card has to be connected in parallel with the opening command, on the
main coil.
1) When the breaker is close and the opening contacts are open, a current circulate
through the resistors in the coil, this current is enough to activate the optical relay.
When any opening contact from external occurs, the optical relay switch off, and the signal
is sent to SFC control that removes the thyristors pulses immediately. The opening time of
the circuit breaker is enough to have the pulses suppression before, hence the breaker
open always without current.
-x_
-x_
86G SFC
-x_
-x_
YO Opening coil
Note: The card works just when is connected on the main opening coil, not when is used
an auxiliary relay as support to open the circuit breaker.
This group includes those cards managing the analog signals for the control; the connection
of these cards is accomplished by means of a multi polar cable with a 25 pin connector,
while towards the field it is obtained by means of a screw terminal board.
The following table shows a brief description of the digital cards.
Transducers
They are divided into current transducers (CT Lem), voltage transducers (magnetic PTs
and lem) and signal transducers.
The current transducers are Hall effect measure transformers assembled on AC side bars
in each converter. As the output signal is in mA, it will suitably processed on the interface
card.
The Hall effect voltage transducers are used on the fixed and variable frequency circuit. As
the output signal is in mA, it will suitably be processed on the interface card.
The function of the signal transducers is that of adapting the signals from and to the control
to the desired value and form.
The following table shows a brief description of the transducers assembled in the drive.
All panel input and output signals are galvanically separated by means of 8 relay terminal
board cards as shown in the figure below, except for the commands to the average voltage
switches that use relays with power contacts.
The coils of input cards and power auxiliary relays are equal to 110Vdc, while input cards
and logic relays are equal to 24Vdc.
Input
From / to
110Vdc 24Vdc PLC and
Relay logic
Output
Galvanic separation
Ensured by the interface cards
The PLC used for this application is a GE FANUC type 90-30 series and it consists of:
- 56 digital input points
- 48 output points
boxes can be supplied, as an option, for:
- analog inputs
- MOD – BUS rtu slave communication
Thanks to the PLC all the panel logic and the communication with the supervision system
are developed.
FRONT
=G3.U01 -AJ
=G3.U01 –AJ01
=G3.U01 –AJ02
FRONT
FRONT
The disconnecting switch is used to be sure of the electrical insulation between the
generator and the inverter during the stand-by condition.
The disconnector switch work automatically, during the start up sequence and the shut
down, by means of a motor drive electric controller activated with the PLC logic.
The opening and closing command are be ensured through the limit switch assembled on
the panel near the gear motor.
The disconnector is equipped with a crank handle used just in case of maintenance.
Any attempt to use the disconnector manually during the SFC operation break off the
sequence.
A safety interlock with generator have to be realized to be sure that every maintenance
operation will be execute in safety condition.
(see operation chapter)
1.3. FUNCTION
LOAD
LINE THYRISTOR
SOURCE CONVERTER MOTOR
REFERENCE
SIGNAL
The requirements of the load can be specified in terms of speed and torque demands. In
order to select a suitable drive for a specific load it is necessary to obtain complete
information about the load requirements,
A motor having speed-torque and speed-current characteristics that suit the load
requirements is chosen. A motor will have characteristics compatible to the load if it
satisfies the speed and torque requirements of the load without exceeding the current
limitation imposed either by the motor rating or the source capacity.
Usually the natural speed-torque characteristic of the motor is not compatible with the load
requirements, for this reason a power converter is interposed between the line source and
the motor. Fig. 1.3.1b shows an example of torque-speed characteristic.
Torque
Speed
The power converter controls the flow of the power from the source to the motor in such a
way that the motor speed-torque and speed current characteristics are compatible with
the load requirements.
The control of the converter is enclosed in a control unit which operates at much lower
voltage and power levels. The control units consists of micropocessor, PLC, lnear and
digital integrated circuits.
The reference signal (ex. seed setpoint ) adjusts the operating point of the drive and it is
an input for the control unit.
The control unit is electrically isolated from the power converter mainly for two reasons:
a) Without isolation a malfunction in the power converter or in the motor may lead to the
application of the power voltage to the control unit damaging the control and may
attempt the safety of the operator during the drive start up tuning or during the
maintenance.
b) Converter generates harmonics, without isolation the harmonics can enter in the
control and interfere with its operation
The sensing of certain quantities as converter current and voltage, motor speed is usually
required for protection and closed loop regulation (speed regulation loop, current
regulation loop) and metering. The sensing transducers of the power converter electrical
quantities are isolated from the control unit for the reasons stated above.
The complete drive system consisting of the load, motor, power converter, line source and
sensing unit should be considered as an integrated system. The power converter should
be selected to make the motor characteristics suitable the load taking into account the line
supply source and rules governing its use, for example it may be necessary to limit the
current inrush during starting to avoid voltage fluctuations on the supply line.
Any motor load system can be described by the following fundamental motion equation:
d m
T TL J (2.1)
dt
where :
T [Nm] developed torque of the motor
TL [Nm] load resisting torque, referred to the motor shaft
J [kgm2] moment of the inertia of the motor-load system referred to the motor shaft
m [rad/sec] instantaneous angular velocity of the motor shaft.
Equation (2.1) shows that the torque T developed by the motor is counterbalanced by the
load torque TL and by the dynamic torque Jdm/dt that is called dynamic torque because it
is present only during transient operation.
The drive accelerates or decelerates depending on whether T is greater or less than T L.
During the acceleration period, the motor shall supply not only the load torque T L but an
additional torque Jdm/dt to overcome the inertia of the motor-load system.
In application having a load with large inertia the motor torque must exceed the load torque
by a large amount to have and adequate amount of acceleration, on the other side in
application requiring fast response, the motor torque should be maintained at the highest
value and the motor-load system should be designed to have the lowest inertia.
When the speed increases, the kinetic energy of the drive ½ J2m also increases, in
addition to the energy supplied to the load, the motor supplies the kinetic energy. During the
deceleration, the dynamic torque Jdm/dt changes its sign, the motion of the drive is
maintained by extracting energy from the stored kinetic energy. When the load has a high
inertia, the motor should produce a large braking torque (T is negative) to have adequate
deceleration, when it is required a fast rersponse, the braking torque should be maintained
at the highest value and the motor-load system should be designed with the lowest possible
inertia.
When motor torque T and load resistant torque TL are known it is possible to solve Eq. 2.1
in terms of time to get the speed vs time curve from speed 1 to speed 2 :
2
J
t ( ) T ( ) T ( ) d
1
L
(2.2)
Fig. 1.3.2a - Motor-drive Torque and Load Torque for Gas Turbine starter application
Fig. 1.3.2a shows an example of load resistant torque TL, note that when the Gas Turbine is
fired resistant torque changes sign becoming motoring torque, the same figure shows the
motor-drive available torque.
Fig. 1.3.2b – Typical Speed vs Time curve for Gas Turbine starting
Fig. 1.3.2b shows an example of Speed vs Time curve obtained by solving the integral
(2.2).
The fully controlled three-phase bridge with thyristor can function as a rectifier or as an
inverter. The converter can, by suitable control, reverse the polarity of the direct voltage, but
not the direction of the direct current.
Two three-phase bridges decoupled on the dc side by and inductor can interconnect two
three-phase systems of different frequencies and voltages, and provide for an exchange of
energy in the two directions. This double-bridge circuit is known also as dc link converter
(Fig.1.3.3.a).
RECTIFIER DC REACTOR
INVERTER
Idc
LINE Ldc
T4 T6 T2
T1 T3 T5
T1 T3 T5
SYNCHRONOUS MOTOR f2
SUPPLY f1 T4 T6 T2
The three-phase bridges may also be connected in series. The direct voltage is then
doubled.
At the same time, by using a star-delta transformer connection, it is possible to obtain
twelve-pulse converter operation, with reduction in harmonics (Fig.1.3.3b).
DC REACTOR
RECTIFIER Idc INVERTER
Ldc T4 T6 T2
T1 T3 T5
L1 Lk L1(R)
L2 Lk L2(S)
LINE L3 Lk L3(T) T4 T6 T2
y U(R) LU Lk"
CB
T4 T6 T2 V(S) LV Lk"
TCV SM
D LW Lk"
FIELD
T1 T3 T5
W(T)
d L1 Lk L1(R) T1 T3 T5
L2 Lk L2(S)
L3 Lk L3(T)
T1 T3 T5
T4 T6 T2
The dc link converter consists of two fully controlled three-phases bridges decoupled by an
inductor in the d.c. circuit. The circuit is known as d.c. link converter, because a direct
current Idc, smoothed by the inductor Ldc, flows between the two bridges (Fig.1.3.4a.)
The operation of the dc link converter is based upon simultaneous current and voltage
loading of both bridges. One bridges functions as a rectifier, the other as an inverter.
RECTIFIER DC REACTOR
INVERTER
Idc
LINE Ldc
T4 T6 T2
T1 T3 T5
TCV L1 Lk L1(R)
VdREC U(R) IMU LU Lk"
CB
L2 Lk IL2 L2(S) V(S) LV Lk"
SM FIELD
L3 Lk L3(T) W(T) IMV LW Lk"
IL3 VdINV
T1 T3 T5
SYNCHRONOUS MOTOR f2
SUPPLY f1 T4 T6 T2
Idc
Fig. 1.3.4b illustrates the operation of the fully controlled d.c. link converter in case where
the two three-phase systems are similar (same frequency, voltage and short circuit
reactances).
The operating point of the inverter is taken to be with = 145°.
The delay angle of the rectifier then has to be set at 18° to obtain the required current at the
given voltage.
The rectifier (vdREC) and inverter (vdINV) direct voltage waveforms, the rectifier (VdREC) and
inverter (VdINV) average values (straight lines) and the line (VLST) and motor (VMRS)
alternating voltages are shown on Fig.1.3.4c.
The dc link current (id) waveform, the average value (Id) of the dc current (straight line), the
line (iLS) and motor (iMR) phase currents are shown on Fig. 1.3.4d.
The two three-phase systems connected by the d.c. link converter can be of quite different
frequencies and short-circuits reactances, and also of unequal voltages.
Fig.1.3.4e shows the currents in the dc link converter fir a case in which the two three-
phase systems have frequency of 50 Hz (rectifier) and 52.5 Hz (inverter). The alternating
currents ILS of the rectifier and IRM of the inverter, and the direct current IDC, are modulated
at six time the frequency of both ac systems (300Hz and 315Hz). If the frequency of the two
ac systems are only slightly different (as in our case), beats are noticeable in the direct
current. In Fig. 1.3.4e is shown the beat frequency which frequency is six time the
difference of the two systems frequency:
In the dc link converter with two controlled three-phase bridges and an inductive dc link
(Fig.1.3.4a) the power can transmitted between the two three-phase systems in either
direction. The direction of the power flow is determined by the manner in which the bridges
are controlled. The rectifier side functions as an energy source, the inverter side as a load.
The power transfer takes places between the a.c. voltage sources of the two systems. Only
the fundamental components (first harmonic) of the currents contribute to the power. The
active power (neglecting the losses of the bridges and dc link reactor) is always the same,
but the non-active powers can differ considerably, they depend upon the control angle of
the rectifier and inverter.
1.4.1 General
A C D
ACPU02
CARD
COM1
The serial link cable, identification code 1000079378 + 1000079381, consists of what
follows:
BLACK
05 05 05
06 BLUE 06 06
04 BLACK 04 04
07 GREEN 07 07
03 BLACK 03 03
08 RED 08 08
02 BLACK 02 02
09 WHITE 09 09
01 01 01
General
SSDTERM is a software tool that permits to carry out a fast and effective analysis
of the speed regulator operation state. It is not located permanently in the system
since it is designed for the heaviest diagnostic analyses such as the system
installation. The system is provided with a segment-type LED (ACPU02) for the
following elementary signals:
This paragraph deals with the description of the SSDTERM programme in WINDOWS
version; the WINDOWS version keeps its setting and the same functions, yet adopting the
graphical look and the command immediacy that are typical of the execution environment.
The programme can be located on the personal computer in a directory other than the
work one, but all the files managed by the programme will be taken and put in the work
directory.
Conditions to start the programme it is necessary to be in WINDOWS environment and
enter:
Choose the correct COM
port and click CONNECT
Menu
After pressing pushbutton "continue" the following image will be shown on the display:
Configuration
1 2 3
4 5
The CONFIGURATION page permits to get access to parameters, variable and control
states and to preset the oscilloscope functions.
The page is essentially subdivided into 5 windows.
Windows no. 2, 3 can be used to get access and, if necessary, to modify the control
parameters and to display their variables.
Windows no. 4, 5 can be used to get access and, if necessary, to modify the control flags.
Window no. 1 is utilized for oscilloscope function pre-setting.
either the drop-down menu located or buttons called PgUp and PgDn located
high on the left down on the right
They permit to scroll the
A B various control pages
within which all its
dimensions are contained
[C] scopE
If “scope” is selected by the following page is shown (fig.5.2.3.4a, b, c):
By this function all the variables existing in the regulator can be displayed in graphic
format.
All right reserved copyright
PARAMETERS
It permits to change the parameters utilized in scales and diagnostic
SAVE
It permits to create a file in which the data present in the Historical Buffer can be
saved.
This file can be seen again selecting the History function
FlaGs
Selecting “Flag” by the following page is displayed.
The menu (Figure 5.2.3.5) permits to display all the inner and input/output logic inner
variables subdivided into 16-bit columns while, at the display base, the selected Flag,
already seen in Configuration menu, is still available.
If the password is enabled, the flags can be modified positioning the cursor on involved
variable that, as only two possible modes are available, can be changed pressing enter.
The only column the values of which can be modified normally is CONTROL; the output
flags can be modified too but only in diagnostic mode (Diag = ON) for the output relay test.
At the display base a help line indicates the available commands:
Press esc to exit the menu.
The code
indicates the
speed regulator
version
History
The menu permits to open one of n saved graphic files.
Selecting “History” by the following page is shown (fig.5.2.3.6a):
VALUES
It permits to display the numeric value of the chosen dimensions.
In order to help the analysis of recording two bars (a blue and a black one) are
available; they are moved by dragging or pressing black and blue >> ,<< buttons
that are located in the middle.
The value taken by each dimension in correspondence with the bars and the time
distance between the two bars can be seen up on the left.
BARS
EXPORT
It permits to export the file for printing purpose or sending by e-mail.
Measure
By means of
mouse
select one or
more of the
following pages
of PC interface:
The variables, that are shown, are the analog input/output of the AINT02 and ACPU02
cards.
Speed regulator
To understand the several parameters is preferred to introduce the speed regulator. The
speed regulation is carry out inside the control card ACPU02, it can be rappresented as below:
Rive Kp
- + Rico
Reve Ki/s
where:
Rive = internal speed reference
Reve = speed feedback
Kp = proportional gain
Ki =integral gain
Rico = current reference
As you can see on the schematic diagram above, for each analog input signal is possible to set
a filter by the set parameters, this issue will be discussed below.
The regulator is connected with the outside through the cards XREVOX as in the following
scheme:
From the output signal of the transducers, are made the signal to achieve the current reference
(RICO) as output of the speed regulator
A more complete scheme for explain the regulator input is the following:
Live Aut.
Rive
Rico
Rive Regulator
Live Man. Ramp PI
+
RiveReg
StepW
Reve Limcor
Aut Man.
The speed regulator can have two types of reference called Rive and RiveReg. Selecting Rive the
regulator will follow the planned reference, which will be created by the external reference and by
the insertion of the selected ramp. Selecting the reference instead RiveReg will have been
overlapped a step defined by the test parameters (stepW, TimeWsec) . This function is used for
trying the answer of the speed regulator.
StepW
TimeW
T T
Live
Rive
RiveReg
Reve
All the defined parameters are present in the various menus of the list parameters that will be
explained in the following pages. The various parameter pages are:
Here below will be done a more detailed explanation of the various parameters page.
In the following menu are present the analogical input signals with the relative parameters of
conditioning. Three types of parameters exist essentially:
Likewise to the preceding menu also this menu represents analogical input greatness in entry to
the ACPU02. As for the preceding greatness, also in this case there are some parameters used
to set the greatness visualization.
The parameters are therefore:
Likewise to the preceding menu the parameters “XXXX 8V = %” is used to define the
percentage for a 8V signal. These two menus contain the analog input variables of the regulator
and the parameters for their visualization.
Menu: ANALOG.OUTPUT
The output "Rico Amp" is the reference sent to the current regulator; the other output signals are
used for the instruments or for other diagnostic systems.
- Instr. FS V
- Instr. FS rpm
- LIVE FS Cal
With the two inputs (Instr. FS V and Instr. FS rpm) the software calculates the corresponding
percentage (LIVE FS Cal) that has to be insert into the box LIVE 8V=%. If the instrument points to
a wrong number the operator can change the parameter LIVE 8V=%.
Menu: MEASUREMENT
This menu is used for diagnostic during the operation, in fact all the parameters are readable [R].
This menu is used to define the parameters of the ramp in the manual operation, as well as the
external references of speed.
In the manual mode there is only one acceleration and only one deceleration, so it’s impossible
to create a profile that change with the speed.
The external references have an hysteresis to avoid continuous changes of the signalling
because of possible oscillations around the value of reference. An example of hysteresis is the
following:
Parameter Parameter
+
hysteresis
As can be observed by the figure above, the flag it will change when the input will assume a
greater value than the parameter plus the hysteresis and it will return to the initial value when
the input signal will assume a smaller value than the parameter inserted. In this way is possible
to avoid continuous changes when is present an oscillations on the signal.
The external references are able by the corresponding digital input, a flag indicate that the
speed it has been reached. Also the various speed reference selected is indicated by a flag.
Rive _
Live E2 rpm Rampa
Digital Input 5
Reve
The speed reference Live E2 rpm can be selected by the digital input 5, the falg Iref2 shows the
selection, when the feedback (REVE) reachs the reference, the output W2RCH will be on.
The various flagses will be explained in the flags list.
The parameters:
- Ext Curr. Lim%
- Dec Amp/ms
- Inc Amp/s
are used when the Ext Curr.Lim% is enable with the digital input 2. When the digital input 2 is on
the Curr.Lim change as the chart below:
Increase Ramp
Inc Amp/s
Decrease Ramp
Dec Amp/ms
Internal Curr.Lim
Curr.Limit
Current
Ext. Curr.Lim
Limite interno
As soon as input 2 becomes ON the Current Limit becomes equal to the current and after that
decreases with the ramp (Dec Amp/ms). When the input 2 becomes OFF the current limit
increases with the ramp (Inc Amp/s).
This menu contains all the necessary parameters to define the accelerations in the motor and
generator operation.
Speed
1 2 3 125%
N = 100%
The acceleration and deceleration characteristics in the generator operation are similar.
This menu is used to define the current limits during the motor operation.
Legend:
1 Speed1 %
Lc4 2 Speed2 %
Lc5 3 Speed3 %
4 Speed4 %
5 Speed5 %
Lc3 6 Speed6 %
7 Speed7 %
Lc1 CurrLim1 %
Lc2 CurrLim2 %
Lc3 CurrLim3 %
Lc4 CurrLim4 %
Lc5 CurrLim5 %
Lc2
Lc6 CurrLim6 %
Lc7 CurrLim7 %
Lc1
Lc6/Lc7
Speed
1 2 3 4 5 6 7 125%
This menu is used to define the inverter firing angle characteristic during the motor operation.
Degrees
Legend:
Agl 2 1 Speed1 %
2 Speed2 %
3 Speed3 %
4 Speed4 %
Agl 3 5 Speed5 %
6 Speed6 %
Agl1 ANGLE1
Agl 1 Agl2 ANGLE2
Agl3 ANGLE3
Agl4 ANGLE4
Agl 4 Agl5 ANGLE5
Agl6 ANGLE6
Agl 5
Agl 6
Speed
1 2 3 4 5 6
This menu is used to define the current limits during the generating operation.
Current
Legend:
1 Speed1 %
2 Speed2 %
3 Speed3 %
4 Speed4 %
Lc1 5 Speed5 %
6 Speed6 %
Lc2 7 Speed7 %
Lc1 CurLim1 %
Lc3 Lc2 CurLim2 %
Lc3 CurLim3 %
Lc4 Lc4 CurLim4 %
Lc5 Lc5 CurLim5 %
Lc6 CurLim6 %
Lc7 CurLim7 %
Lc6/Lc7
Speed
1 2 3 4 5 6 7 125%
This menu is used to define the inverter firing angle characteristic during the generating operation.
The parameters Brake and Din. Brake allow to recovery energy to the incoming line when the
motor decelerate (Din. Brake) or when brake (Brake). When Din. brake is 0 the machine decrease
its speed per inertia until there is an emergency brake (Brake = 1).
For the plant in examination the angle assumes this values:
Angle Legend:
1 Speed1 %
2 Speed2 %
3 Speed3 %
Agl1 4 Speed4 %
Agl2 5 Speed5 %
6 Speed6 %
Agl3 Agl1 Angle1
Agl4 Agl2 Angle2
Agl5 Agl3 Angle3
Agl4 Angle4
Agl6
Agl5 Angle5
Agl6 Angle6
Speed
1 2 3 4 5 6
The parameters that can be inserted concern the constants of the proportional and integral
actions of the speed regulator. As can be noticed by the chart, it can be inserted several
constant at different speed. Another important parameter is DeltaGen A that it represents a
threshold of current necessary to discriminate the generator operation from motor operation.
A typical characteristic gain-speed :
gain
Kp2
Legend:
1 Speed1 %
2 Speed2 %
Kp1 Prop.Gain1
Kp2 Prop.Gain2
Ki1 Int.Gain1
Ki2 Int.Gain2
Ki2
Kp1
Ki1
Speed
1 2
Another important parameter is CUR. LIM. Flt that consists of a filter inserted on the current
limit. It is used to have a sweet current at the start up. The chart below represents the time
constant that corresponds to the parameter:
Current limit
CUR.LIM.Flt
5 xCUR.LIM.Flt
After 5xCUR.LIM.Flt the filter is equal to the current limit. This filter is always inserted and it is
forced to zero at the start up or when there is the passage from motor mode to generator mode.
The parameter Xintegrale is used to increase/decrease rapidly the integral action when the speed
error changes its sign.
Xintegrale
used
Proportional action
Integral action
+ Deltagen
This menu is used to set the speed threshold to define the different phase of operation.
The parameter 1LiveRive> is used to enable the output signal RICO%. When the speed reach the
value set by the parameter W RpCn the operation of the regulator passes from pulse regim to
natural commutation. The suppression of the pulses happens instead through the parameter
W = 0%. The following figure shows the regulator operation:
W =0
1LiveRiv
e
Natural commutation
Turn off
regulator
Enable regulator
Each speed parameter have an hysteresis that permit to the regulator to work properly.
In this menu is possible to set the current limit to avoid to overload the machine during the
operation. The overload is calculated by the formula below:
I
2
I t statore
2
1dt
Ilimitestatore
Where:
Istatore = stator current
Ilimite-statore = stator current limit (CurrLim)
I2t = overload area
The relationship between the stator current and its limit is the overload (OVL)
For example:
If the motor have an overload possible of 150% for 30s (tOVL), the area I2t will be:
Therefore it’s possible to calculate the max time for the overload:
I2 t TRIP
t
OVL2 1
The characteristic is inversely proportional with the overload value.
An example of the relationship between overload and time of intervention is represented by the
following graph:
overload
CURVA DI SOVRACCARICO
10000
1000
t [s]
100
10
1 1,05 1,1 1,15 1,2 1,25 1,3 1,35 1,4 1,45 1,5
OVL [p.u.]
Knowing the value of the admitted area and calculating the percentage of overload is possible to
define the time of intervention of the protection.
The thermal protection is modified in base to the speed of rotation, because the ability of cooling
comes to be reduced at low speeds.
Curr3/Curr4
Curr5 Legend:
Curr6/Curr7 1 Speed1 %
2 Speed2 %
Curr2 3 Speed3 %
4 Speed4 %
5 Speed5 %
6 Speed6 %
7 Speed7 %
Curr1 CurrLim1%
Curr2 CurrLim2%
Curr3 CurrLim3%
Curr4 CurrLim4%
Curr1
Curr5 CurrLim5%
Curr6 CurrLim6%
Curr7 CurrLim7%
ω1 ω2 ω3 ω4 ω5 ω6 ω7 125%
The protection I2T is used for avoiding overheating to the rotor of the machine.
Likewise to the preceding menu also this menu represents the thermal protection but this menu
concern of the rotor of the machine.
Menu: TESTING
The parameters AREA S A2T & AREA R A2T are used to define the overload area for the I2T
protection (37,5 means 150% of overload for 30s). The parameters I2T ab.% I2Te En% and
P.MaxSpeed enable the protections.
The answer to the step is verified with the parameters StepW and TimeWsec that go to work on
the signal of the regulator (RiveReg).
The parameters Ntg % and Prop % are the actions of the regulator.
The Flags are used for monitoring the regulator operation and enable the function available.
Also for the flags are present several menu, explained below:
CONTROL Function available
STATUS Status variable
INP_EXT1 External input for enabling function
IN_AINT1 Input signals AINT02
IN_ACPU1 Input signals ACPU02
OUT_EXT1 Output
OU_AINT1 Output AINT02
OU_AINT2 Output AINT02
OU_ACPU1 Output ACPU02
OU_ACPU2 Output ACPU02
Menu: CONTROL
Menu: STATUS
Menu: INP_EXT1
Menu: IN_AINT1
Menu: IN_ACPU1
Menu: OUT_EXT1
Menu: OU_AINT1
Menu: OU_AINT2
Menu: OU_ACPU1
Menu: OU_ACPU2
Repairs for fault operation should not be necessary (other than in the case of
electric or mechanical wear of the components) if maintenance is carried out
efficiently. The system is correct if installation of the equipment complies with the
limits declared by the Manufacturer.
In general, the most frequent repair is the replacement of the signalling lamps.
The initial tests performed by the program of the ACPU02 microcontroller card are:
All hardware protections are realized with electronic comparators tripping at the voltage
thresholds that can be calibrated by means of resistors.
All protections are stored to the APROT3 card and displayed through a DISPLAY.
Five digital signal on the output of the cards APROT3 indicate which protection occurred.
The PLC use these signals to indicate on the message display which fault is occurred.
The table below explain for each digital combination the right meaning.
PROTECTION TABLE
00 No protection 0 0 0 0 0
02 Available 0 1 0 0 0
07 Differential current Υ – Δ 1 1 1 0 0
15 Software trip 1 1 1 1 0
17 N° 2 Thyristors fault 1 0 0 0 1
Differential current
19 1 1 0 0 1
input transformer
Differential current
20 0 0 1 0 1
output transformer
21 Ground fault 1 0 1 0 1
Cause
The input voltage exceed the 110% of the rated voltage
(the tripping threshold can be customized on the card APROT3)
Action
2 Max line voltage Check the value of the input voltage by means of an external
transducer.
Check the wiring between TV LEM and XREV.. card
Check the electronic cards that elaborate the voltage signal
(XREV.. - AREV.. - APROT3)
Cause
The input voltage is lower the 90% of the rated voltage
(the tripping threshold can be customized on the card APROT3)
Action
3 Min line voltage Check the real presence of the input voltage by means of an
external transducer.
Check the wiring between TV LEM and XREV.. card
Check the electronic cards that elaborate the voltage signal
(XREV.. - AREV.. - APROT3)
Cause
The input current exceed the 110% of the rated current
(the tripping threshold can be customized on the card APROT3)
rated I'dc = 6V average, trip calibrated at 9.12V 0.1V peak
Action
4 Max current 1 star Check the connection between CT Lem and XREV.. card.
Check the CT Lem power supply.
By means of a multimeter, check the thyristors of the rectifier
bridge; if the thyristor is in short circuit, it is spoiled.
Check the electronic cards that elaborate the voltage signal
(XREV.. - AREV.. - APROT3)
Current peak where the
comparator is calibrated
DC CURRENT 6V
SIGNAL average
Differential
6 current Υ – Δ
- NOT APPLICABLE
Cause
The difference between the inverter current and the rectifier
current exceed 10% of the rated current.
The tripping threshold can be customized on the card APROT3
Rated I'dc = 6V average, trip calibrated at 0.92V 0.1V
Differential Action
7 current Idc1<Idc2 Check the connection between CT Lem and XREV.. card.
Check the CT Lem power supply.
By means of a multimeter, check the thyristors of the rectifier
bridge; if the thyristor is in short circuit, it is spoiled.
Check the electronic cards that elaborate the voltage signal
(XREV.. - AREV.. - APROT3)
Cause
The difference between the rectifier current and the inverter
current exceed 10% of the rated current.
The tripping threshold can be customized on the card APROT3
Rated I'dc = 6V average, trip calibrated at 0.92V 0.1V
Differential Action
8 current Idc2<Idc1 Check the connection between CT Lem and XREV.. card.
Check the CT Lem power supply.
By means of a multimeter, check the thyristors of the rectifier
bridge; if the thyristor is in short circuit, it is spoiled.
Check the electronic cards that elaborate the voltage signal
(XREV.. - AREV.. - APROT3)
Cause
The inverter current exceed the 125% of the rated current.
The tripping threshold can be customized on the card APROT3
Rated I'dc = 6V average, trip calibrated at 9.12V 0.1V
Action
Max Current
9 motor side
Check the connection between CT Lem and XREV.. card.
Check the CT Lem power supply.
By means of a multimeter, check the thyristors of the rectifier
bridge; if the thyristor is in short circuit, it is spoiled.
Check the electronic cards that elaborate the voltage signal
(XREV.. - AREV.. - APROT3)
DC CURRENT 6V
SIGNAL average
DC
Current
Differential
L current Input - NOT APPLICABLE
Transformer
Differential
P current Output - NOT APPLICABLE
Transformer
Max. current
J High voltage side - NOT APPLICABLE
input Transformer
Max. current
High voltage side
11 output
- NOT APPLICABLE
Transformer
LINE 1
LINE 2
LINE 3
LINE 4
F1 F2 F3 F4
Page 2
with F1 pushbutton is possible to change the operation mode :
AUTOMATIC MODE [standard mode]
SELECTION MODE SHORT CIRCUIT TEST [ test mode ]
With F2 pushbutton is enabled the start of the test .
With F3 pushbutton is enabled the stop of the test.
F4 pushbutton is not used
Page 3
with F1 pushbutton is possible to enable / disable the test.
COOLING FANS TEST With F2 pushbutton is enabled the start of the test.
With F3 pushbutton is enabled the stop of the test.
F4 pushbutton is not used
Page 4
EVENT LIST with F1 pushbutton is possible to see the alarm list.
With F2 pushbutton is possible to clear the alarm list
With // pushbutton is possible to go out of the page.
INPUT V LINE The message inform that the power connections of the
REVERSE SEQUENCE network side are not connected correctly.
LOCAL EMERGENCY This block is caused by the emergency head placed on the
PUSHBUTTON SB02 control compartment door.
TIMEOUT EXCITATION This is a signaling to inform the personnel that the Exciter 1
SYSTEM 1 NOT READY is not ready to start.
TIMEOUT EXCITATION This is a signaling to inform the personnel that the Exciter 2
SYSTEM 2 NOT READY is not ready to start.
AIR FILTERS CLOGED The shelter filters in the transformer zone are dirty.
ZONE C It is necessary to change it for a go air exchange.
MAXIMUM INPUT For this signal see paragraph 1.5.4 Hardware Protections
VOLTAGE > 110% (2)
MINIMUM INPUT For this signal see paragraph 1.5.4 Hardware Protections
VOLTAGE < 85% (3)
MAXIMUM RECTIFIER For this signal see paragraph 1.5.4 Hardware Protections
CURRENT (4)
DIFFERENTIAL CURRENT For this signal see paragraph 1.5.4 Hardware Protections
I’DC < I”DC (7)
DIFFERENTIAL CURRENT For this signal see paragraph 1.5.4 Hardware Protections
I”DC < I’DC (8)
MAXIMUM INVERTER For this signal see paragraph 1.5.4 Hardware Protections
CURRENT (9)
MAXIMUM MOTOR For this signal see paragraph 1.5.4 Hardware Protections
VOLTAGE > 110% (A)
MINIMUM EXCITATION For this signal see paragraph 1.5.4 Hardware Protections
CURRENT < 10% (b)
MAXIMUM EXCITATION For this signal see paragraph 1.5.4 Hardware Protections
CURRENT > 120% (C)
GENERATOR WRONG For this signal see paragraph 1.5.4 Hardware Protections
ROTATION (d)
ACPU02 FAULT For this signal see paragraph 1.5.4 Hardware Protections
TRIP SOFTWARE (E)
MAXIMUM SPEED For this signal see paragraph 1.5.4 Hardware Protections
(H)
Board connections involve both auxiliary/control cables and power cables designed to
carry high currents.
Auxiliaries/control connections are carried to terminal blocks, while power connections are
carried to copper bus bars of adequate section.
In the specific case board is arranged as follows:
- Power cubicle Terminal block -XT12P Power input mains from m.v.
switchboard and Generator fielding
- Auxiliary cubicle Terminal block -XT21A1 Analog I/O signals
- Auxiliary cubicle Terminal block -XT21A 240/415V 50 Hz auxiliary power
supply
- Auxiliary cubicle Terminal block -XTGT1 Digital INPUT / OUTPUT signals from
gas turbine 1
- Auxiliary cubicle Terminal block -XTGT2 Digital INPUT / OUTPUT signals from
gas turbine 2
- Auxiliary cubicle Terminal block -XTEX Digital INPUT / OUTPUT signals from
external circuit breaker
- Auxiliary cubicle Terminal block -XT21P Internal interconnections
- Auxiliary cubicle Terminal block -XT21 Internal interconnections
Terminal block location may be see on drawing 2FN1000132875C sheet: 070 – 071 that is
an integrant part of functional diagram.
Board shall be grounded by means of ground copper bar – WB01(PE) that is longitudinal
to the board.
Such bar shall be connected to plant grounding system by the installer.
Position Main Circuit Breaker [ 52G_position ] Contact NC 11,5kV M.C.B. Open status -XTGT1 - 12 - 18
Position Earth ext starting switch [ 89SS_1.1 pos ] Contact NC Earth status -XTGT1 - 15- 21
11,5kV Earthing.
Position ext. starting switch [ 89SS_1.1 opened ] Contact NC Open status -XTGT1 - 13 - 19
Disconnector
Position ext. starting switch [ 89SS_1.1 closed] Contact NO Close status -XTGT1 - 14 - 20
Exciter Angle Reference [ START FLS CURR ADJ_1 ] (420mA) Exciter 1 20mA = no load Curr. -XT21A1 - 21- 22
22)) S
STTA
ATTIIC
CSSTTA
ARRTTE
ERR [[ S
SFFC
C –– G
GTT22 ]]
DIGITAL INPUT Signal Type From Notes Terminal Board
Black start selection Contact NO GTC 2 -XTGT2 - 01 - 04
Normal Start / Stop [ 4CSF-2 ] Contact NO GTC 2 -XTGT2 - 02 - 05
External Trip [ SFC TRIP 2 ] Contact NO Generator protect. 2 -XTGT2 - 03 - 06
Position Main Circuit Breaker [ 52G_position ] Contact NC 11,5kV M.C.B. Open status -XTGT2 - 12 - 18
Position Earth ext starting switch [ 89SS_2.2 pos ] Contact NC Earth status -XTGT2 - 15- 21
11,5kV Earthing.
Position ext. starting switch [ 89SS_2.2 opened ] Contact NC Open status -XTGT2 - 13 - 19
Disconnector
Position ext. starting switch [ 89SS_2.2 closed] Contact NO Close status -XTGT2 - 14 - 20
Exciter Angle Reference [ START FLS CURR ADJ_2 ] (420mA) Exciter 2 20mA = no load Curr. -XT21A1 - 26- 27
CSF GENERATOR
CONTROL PANEL 1
-XTGT1 03-06 Input External Trip 1 [SFC TRIP 1 ] Output
-XTGT1 46-48 Output CSF transformer alarm Input
-XTGT1 49-51 Output CSF transformer trip Input
GENERATOR
CONTROL PANEL 2
-XTGT2 03-06 Input External Trip 2 [SFC TRIP 1 ] Output
-XTGT2 46-48 Output CSF transformer alarm Input
-XTGT2 49-51 Output CSF transformer trip Input
SPEEDTRONIC GT2
-XTGT2 02-05 Input Normal Start/Stop [4CSF-2 ] Output
-XTGT2 01-04 Input Black start selection Output
-XTGT2 40-42 Output CSF Alarm [30CSF-2] Input
-XTGT2 31-33 Output CSF Trip [86CSF-2] Input
-XTGT2 37-39 Output CSF Ready [3CSF-2] Input
-XTGT2 43-45 Output CSF Running [52CSF-2] Input
-XTGT2 52-55 Output Status Earth Switch Isol. 52FV
Input
[57SFC] [57SFC] [52FVCSF-ES-2]
Input ( 4 20 mA ) Speed Reference [77-CSF-2 ] Output ( 4 20 mA )
11,5kV EARTHING
SWITCH GT2
-XTGT2 15-21 Input Status switch 89SS Earth [89SS_2.2 pos] Output
-XTGT2 13-19 Input Status switch 89SS Open [89SS_2.2 opened] Output
-XTGT2 14-20 Input Status switch 89SS Close [89SS_2.2 closed] Output
-XTGT2 24-25 Output Closing command 89SS [89SS_2.2 closing] Input
-XTGT2 26-27 Output Opening command 89SS [89SS_2.2 opening] Input
EXCITER GENERATOR 1
Input ( 4 20 mA ) Exciter Current Measure [STAR FLDCURRMEAS_1] Output ( 4 20 mA )
Output ( 4 20 mA ) Exciter Angle Reference [START FLS CURR ADJ_1] Input ( 4 20 mA )
-XTGT1 16-22 Input Consent Vgen. Minimum [STATORVOLT CHK_1] Output (Vgen<1600)
-XTGT1 17-23 Input Exciter Ready [EXCIT START RDY_1] Output
-XTGT1 28-29 Output Start/Stop Request [EXCIT START CMD_1] Input
EXCITER GENERATOR 2
Input ( 4 20 mA ) Exciter Current Measure [STARTFLDCURRMEAS_2] Output ( 4 20 mA )
Output ( 4 20 mA ) Exciter Angle Reference [START FLS CURR ADJ_2] Input ( 4 20 mA )
-XTGT2 16-22 Input Consent Vgen. Minimum [STATOR VOLT CHK_2] Output (Vgen<1600)
-XTGT2 17-23 Input Exciter Ready [EXCIT START RDY_2 Output
-XTGT2 28-29 Output Start/Stop Request [EXCIT START CMD_2] Input