Mark-VI-Operation Screenshots.pdf

GE Oil & Gas Oil & Gas Industry Applications

CONTROL SYSTEMS

Mark VI OPERATION

Index • Turbine and Auxiliaries • Mark VI - Hardware • Toolbox • Controller – Toolbox - Cimplicity • Screens and Sequences • Troubleshooting

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Index Turbine and Auxiliaries  Gas Turbine review amd working principles • General Information • Turbine applications • Product families • Parts and functioning • Brayton Cycle • ISO conditions • Power shaft managing • Turbine enclousure sensors 

Auxiliaries review and P&I • Auxiliaries • P&I



Network overview • Control system wiring and communication ways

3 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles General information

A ‘Gas Turbine’ is a rotating engine, able to continuously convert thermal energy into mechanical energy

•

High specific power engine (light and powerful machines)

•

High speed rotating machine (3.000 ÷ 30.000 rpm)

•

Capable to drive electrical power generators (GD = Generator Drive applications) or pumps & compressors (MD = Mechanical Drive applications)

•

Used also to power aircrafts or ships

•

Output Power ranges from 100kW up to ~500MW

•

Efficiency ranges from 25% to 43%

•

May use a wide variety of fuels (both gas and liquid types)

•

It may be operated continuously, without any stop, up to one year 4 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Turbine applications Pipeline inspection device

Oil/Gas field Offshore production platform Re-injection plant

Oil / gas processing plant Subsea equipment

Gas boosting station

Power generation plant Oil boosting station

Natural Gas storage plant LNG liquefaction plant

Refinery / Petrochemical / fertilizer plant

LNG receiving plant

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Turbine and Auxiliaries Gas Turbine review and working principles Product families

JET

“PURE AERONAUTICAL” HEAVY DUTY

SINGLE SHAFT

“PENGUIN TURBINES”

DOUBLE SHAFTS

INDUSTRIAL & MARINE USE LM SERIES INDUSTRIAL USE

INDUSTRIAL USE PGT/GE SERIES 6 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles GE 5-1

5.5 MW

GE 5-2

5.6 MW

GE 10-1 GE 10-2 LM 1600/PGT 16 LM 2000/PGT 20 LM 2500/PGT 25 MS 5001PA MS 5002C MS 5002E LM 2500+/PGT 25+ MS 5002D MS 6001B LM 6000 MS 7001EA MS 9001E

 High Efficiency, Reliability & Availability  Low Life- Cycle Costs  Application Flexibility  Fuel Flexibility  Low Emissions

11.2 MW 11.7 MW 14.2 MW 18.1 MW 23.2 MW

26.3 MW 28.3 MW 30.0 MW 31.3 MW 32.5 MW 42.1 MW 43.0 MW 85.1 MW 123.4 MW

Multi Shaft Single Shaft 7 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Parts and functioning

FUEL

1.

Suction

2.

Compression

3.

Combustion

4.

Expansion

5.

Exhaust

FUEL

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Turbine and Auxiliaries Gas Turbine review and working principles Parts and functioning

Combustion system HP Turbine

Front Frame Axial Compressor

Coupling

AGB

Comp. Rear frame

LP Turbine HSPT Turbine Mid Frame 9 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Parts and functioning

INLET

COMPRESSOR

COMBUSTOR

TURBINE

TEMPERATURE

PRESSURE

EXHAUST

TEMPERATURE

PRESSURE

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Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

The Brayton cycle is characterized by means of two parameters:

Compressor pressure ratio

Firing temperature

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Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

The thermodynamic cycle according to with a gas turbine works is known as Brayton cycle. 3 T

C - Compression H - Heating E - Expansion 1

2

H

3

C

E

Cooling 1–2: 2–3: 3–4: 4–1:

Isentropic Compression Constant pressure Heating Isentropic Expansion Constant pressure Cooling

2

4

4

1 S Assumptions: • Ideal gas • Constant specific heat value cp • All processes are reversible • No pressure drops • Constant mass flow 12 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

NOTE: entropy Entropy is a thermodynamic property that is the measure of a system’s thermal energy per unit temperature that is unavailable for doing useful work. During this work, entropy accumulates in the system, which then dissipates in the form of waste heat.

In classical thermodynamics, the concept of entropy is defined phenomenologically by the second law of thermodynamics, which states that the entropy of an isolated system always increases or remains constant. 13 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Specific Work means ‘Work per unit of mass’

T

Useful Specific Work is: Wout = Wexp – Wcomp where: Wexp = h3 – h4 = cp ( T3 – T4 ) Wcomp = h2 – h1 = cp ( T2 – T1 )

3

Qin

Wexp 2

Wcomp

According to the 1st principle of thermodynamics: Wout = Qin – Qout where: Qin = h3 – h2 = cp ( T3 – T2 ) Qout = h4 – h1 = cp ( T4 – T1 )

4 Qout

1 S

The efficiency of the ideal cycle is:

=

𝜂𝜂𝑖𝑖𝑖𝑖 =

𝑊𝑊𝑜𝑜𝑜𝑜𝑜𝑜 𝑊𝑊𝑒𝑒𝑒𝑒𝑒𝑒 − 𝑊𝑊𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = = 𝑄𝑄𝑖𝑖𝑖𝑖 𝑄𝑄𝑖𝑖𝑖𝑖

𝑄𝑄𝑖𝑖𝑖𝑖 − 𝑄𝑄𝑜𝑜𝑜𝑜𝑜𝑜 𝑄𝑄𝑜𝑜𝑜𝑜𝑜𝑜 𝑻𝑻𝟒𝟒 − 𝑻𝑻𝟏𝟏 =1− = 𝟏𝟏 − = … 𝑄𝑄𝑖𝑖𝑖𝑖 𝑄𝑄𝑖𝑖𝑖𝑖 𝑻𝑻𝟑𝟑 − 𝑻𝑻𝟐𝟐

𝜼𝜼𝒊𝒊𝒊𝒊 = 𝟏𝟏 −

𝟏𝟏

𝜸𝜸 𝜸𝜸−𝟏𝟏 𝜷𝜷

Therefore, ηid is only dependant on: • the pressure ratio ( β = p2 / p1 ) • the nature of gas (γ) 14 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Efficiency & Useful Work Once set T1 and T3, Wout and ηid can be plotted as functions of β:

β Wmax

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Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Heating

P 2

Expansion

• Real gas • Specific heat values vary depending on temperature and nature of fluid. • Processes are not reversible • Pressure drops • Compressions and expansions are not isentropic.

3

1 Compression

Cooling

4 Cooling

V

Moreover, a Gas Turbine works in the following conditions: •

an open cycle, so an assumption must be made about the exhaust gases to be cooled by the atmosphere

•

a combustion chamber in place of the heat exchanger, so the mass flow is not really constant (due to the amount of fuel added), even if its variation can be considered negligible

Air Intake 1

fuel

Exhaust CC

3

4

2

C

T C - Compressor CC - Combustion Chamber T - Turbine 16 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Air Intake 1

T fuel CC 2

Exhaust 3

3

Qf 4 2

C

T

4’

2’ 4

W’c

W’t

Qexh

1 S

W’t < Wexp W’c > Wcomp W’c

= cpm1-2 (T2’ - T1)

[Kj/Kgair]

W’t

= cpm3-4 (T3 - T4’)

[Kj/Kggas]

Qf

= cpm2-3 (T3 - T2’)

[Kj/Kggas]

Qexh = cpm4-1 (T4’ - T1)

[Kj/Kggas]

𝜂𝜂𝑟𝑟 =

𝑄𝑄𝑓𝑓 − 𝑄𝑄𝑒𝑒𝑒𝑒𝑒 𝑄𝑄𝑒𝑒𝑒𝑒𝑒 =1− 𝑄𝑄𝑓𝑓 𝑄𝑄𝑓𝑓

cpm is the average specific heat value between the two considered temperatures 17 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Air Intake 1

C

T fuel CC 2

Exhaust 3

4

T

3

Qf 4’

2’ 2

4

W’c

W’t

Qexh

1 S

The Useful Power (Shaft Power) is defined as: Pu = Ggas W’t - Gair W’c [ Ggas = Gair + Gfuel ] G = Mass flow 18 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Once set T1 and T3, W’out and η are here plotted as functions of β:

Increasing the pressure ratio β, while W’ has almost the same behavior as in the ideal case, the efficiency η increases up to its highest value and then decreases.

β1

β2

•

β1 matches to the maximum work, but it relates to a poor efficiency

•

β2 corresponds to the highest efficiency, but a lower work is delivered to the load

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Turbine and Auxiliaries Gas Turbine review and working principles Brayton Cycle

Air Intake 1

T

fuel

Exhaust CC

3

3 4

3’

Qf

2

4’

W’t

2’ C

T

2 W’c

4

Qexh

Considering also the effects of: 1 • pressure drops in the combustion chamber (2’ - 3’) S • backpressures in the exhaust section (4’ - 1) The two main parameters affecting the the useful power is even lower than expected! useful power delivered by a GT are: Those effects are often small, but not always negligible

• •

the actual pressure ratio (β=p2/p1) and, above all, the highest temperature achieved during the process (T3), which is called firing temperature. 20 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles ISO conditions

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Turbine and Auxiliaries Gas Turbine review and working principles ISO conditions

Ambient Temperature

Tamb ↑ ⇒ Pout ↓

As the compressor inlet temperature increases, the specific compressor work increases and the weight of the delivered air decreases (decreasing of the specific weight). Consequently the turbine efficiency (and usefull work) decreases. 22 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles ISO conditions

Atmospheric Pressure (Altitude)

Patm ↑ ⇒ Pout ↓

As the compressor inlet pressure increases, the specific compressor work increases and the weight of the delivered air decreases (decreasing of the specific weight). Consequently the turbine output power, that depends on the air specific weight, decreases. 23 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles ISO conditions

Specific Humidity

Humidity ↑ ⇒ Pout ↓

The air with high umidity rate is less dense than dry air. Consequently the turbine output power, that depends on the air specific weight, decreases. 24 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Power shaft managing

HD single shaft

A classical operating application of single shaft gas turbines is to drive alternators, because in this application there is the need to regulate power at constant rpms (network frequency).

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Turbine and Auxiliaries Gas Turbine review and working principles Power shaft managing HD double shaft

Two Shaft Gas Turbines, as MS5002, need only the HP rotor to rotate at constant speed (5100 rpm), while the Power Turbine speed may change responding to load speed needs, by means of variable nozzle partitions.

With variable nozzles in open position, upmost power is used by the HP turbine.

COMBUSTORS

HP

VARIABLE NOZZLES OPEN

COMBUSTORS

LP

HP

VARIABLE NOZZLES CLOSED

LP

As variable nozzles moves towards a close position, more power is made available to the LP turbine. 26 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Power shaft managing

Aeroderivative double shaft

• • • • •

Gas Generator turbine drives axial compressor and turbine auxiliary by means of gearbox. Power Turbine drives load, usually a centrifugal compressor or a pump, not often an electric generator. PT e GG works at different speed. GG and PT speed change during operation according request of Power from load. For this type of engine variable vanes are installed on axial compressor. In this way varying the angle α of this vane it’s possible control the dynamic of fluid of this component avoiding surge and stall a not design speed. Jet Turbines to increase power output on LP need to increase speed of GG. In this way the control of power for jet turbines is obtained simply controlling the fuel 27 13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles Turbine Enclosure sensors (Aeroderivative example)

Air Inlet Filter • PDT/PDI • Position Switches • Gas detectors • Water Level sensor

Air Fans • Main/Aux selection • ON/OFF command Compartment dampers • Position switches

Gear Box • Temperature sensors • Axial displacement sensors • Radial vibration sensors • Key phasor sensor • Acceleromiters Round down tank • Level sensor Min. oil vap. separator • Fan ON/OFF

Hydraulic starting console • Starting motor ON/OFF • LVDT (valve position) • PDT/PDI • Temperature sensors • Cooler fan ON/OFF • Level sensor Syntetic oil tank/console • Temperature sensors • Heaters ON/OFF • Level sensor • PDI

Min. oil vap. separator • Fan ON/OFF • PDI • Temperature sensors

Enclosures • PDT/PDI • Gas detectors • Temperature sensors • UV detectors • Horns/lights

Mineral oil tank • PDT/PDI • Temperature sensors • Level sensor • Heaters ON/OFF • Pumps ON/OFF

Compressor (load) • Temperature sensors • Radia vibration sensors • Axial displ. Sensors • Seal gas system: • PDT/PDI • Heaters • Temperature sensors

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Turbine and Auxiliaries Auxiliaries review and P&I Auxiliaries

A B C D E F G

INTAKE SYSTEM EXHAUST SYSTEM LUBE AND CONTROL OIL SYSTEM FUEL SYSTEM COOLING AND SEALING AIR SYSTEM BASEPLATE STARTING SYSTEM

H I J L M N P Q

AUXILIARY GEAR LOAD GEAR COUPLING ELECTRIC PLANT ENCLOSURE VENTILATION SYSTEM OIL COOLING SYSTEM CONTROL AND PROTECTION SYSTEM C

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Turbine and Auxiliaries Auxiliaries review and P&I P&I

HD turbine topics (1605987)

P&I reference

FUEL GAS SYSTEM

SOM51047.10

COOLING AND SEALING AIR SYSTEM

SOM51047.20

CONTROL AND PROTECTION SYSTEM

SOM51047.21

LUBE OIL AUXILIARY SYSTEM

SOM51047.30

LUBE OIL TURBINE SYSTEM

SOM51047.30

HYDRAULIC OIL SYSTEM

SOM51047.30

CONTROL OIL SYSTEM

SOM51047.30

LUBE OIL COMPRESSOR SYSTEM

SOM51047.31

OIL VAPOUR SEPARATOR SYSTEM

SOM51047.34

OIL AIR COOLER SYSTEM

SOM51047.36

STARTING MEANS SYSTEM

SOM51047.43

SEAL OIL SYSTEM

SOM51047.60

COMPRESSOR PROCESS DYAGRAM

SOM51047.62

FILTER HOUSE SYSTEM

SOM51047.71

VENTILATION SYSTEM

SOM51047.80

FIRE FIGHTING PAKAGE SYSTEM

SOM51047.81

FIRE FIGHTING SKID SYSTEM

SOM51047.90

WASHING WATER SYSTEM

SOM51047.94 30 13/11/2014

Turbine and Auxiliaries Auxiliaries review and P&I P&I

JET turbine topics (1608994)

P&I reference

FUEL GAS ANALYSER SYSTEM

SOM5106510

FUEL GAS SYSTEM

SOM5106510

FUEL GAS ON ENGINE SYSTEM

SOM5106510

GAS GENERATOR CONTROL DEVICE SYSTEM

SOM5106521

POWER TURBINE CONTROL DEVICE SYSTEM

SOM5106521

MINERAL OIL CONSOLE SYSTEM

SOM5106531

MINERAL OIL TURBINE SYSTEM

SOM5106531

LUBE OIL COMPRESSOR SYSTEM

SOM5106531

SYNTETIC OIL BASEPLATE SYSTEM

SOM5106533

SYNTETIC OIL CONSOLE SYSTEM

SOM5106533

OIL VAPOUR SEPARATOR SYSTEM

SOM5106534

OIL COOLER SYSTEM

SOM5106536

OIL STORAGE AND TREQATMENT SYSTEM

SOM5106538

DIAGRAM OIL CONDITIONING SKID

SOM5106538

HYDRAULIC STARTING SYSTEM

SOM5106541

SEAL GAS SYSTEM

SOM5106560

SEAL GAS BOOSTER SYSTEM

SOM5106560

DIAGRAM N2 SYSTEM

SOM5106560 31 13/11/2014

Turbine and Auxiliaries Auxiliaries review and P&I P&I

JET turbine topics (1608994)

P&I reference

PROCESS FLOW

SOM5106562

FILTER HOUSE SYSTEM

SOM5106571

VENTILATION SYSTEM

SOM5106580

FIRE FIGHTING SYSTEM

SOM5106590

WASHING WATER SYSTEM

SOM5106594

Instrument list: • HD turbine (1605987): • JET turbine (1608994):

SOM6623237 SOM5461221

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Turbine and Auxiliaries Network overview Control system wiring and communication ways network HMI

UDH EXT. POWER

COMPRESSOR PLC

F&G SIS

MCC

Mark VI BN

MP

AUXILIARY

TURBINE

GEAR BOX

COMPRESSOR 33 13/11/2014

Turbine and Auxiliaries Network overview Control system wiring and communication ways

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Mark VI - Hardware Mark VI - Hardware 

Panel introduction • Functioning overview • Main Parts • Power distribution



Simplex – TMR, redundancy and voting process • Rack arrangement • Simplex-TMR connections • Level of redundancy • Output processing • Input processing • Voting principles



VME rack(s) and protection module • VME rack cards and relative termination boards • Protection loop

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Mark VI – Hardware Panel introduction Functioning overview Mark VI is used for the control and protection of steam and gas turbines both in electrical generation and process plant applications.

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Mark VI – Hardware Panel introduction Simplex

Main parts

2

2 1

1r

4 3

1s

1. VME rack r. Rack R s. Rack S t. Rack T 2. Protection Module 3. Terminal Boards 4. PDM

6

5. DACA1 (AC/DC) 6. Input filters

1t 5

37 13/11/2014

Mark VI – Hardware Panel introduction Power distribution Protection module (X, Y, Z) Control terminal board VME rack (R) floating dc bus VME rack (S) Resistor bridge

VME rack (T)

PDM 125 VDC

Boards

Input LP FILTERS AC/DC

230 / 115 VAC (50 / 60 Hz) 38 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Rack arrangement

VME Rack controller

Power supply

01

02

03

04

05

06

07

08

09

10

VME Rack VME bus (Versabus Module Europcard)

UCVx: it is the brain of the sistem, this microprossored board collects all the field input signals and elaborates the necessary output commands. I/O cards: these cards (there are several types depending on the specific function). Input: they acquire the field signalc (digital and analog) and send them on the Vme bus. Output: they receive the output commands (implemented by the UCVx) from the VME bus and interface them with the field. 39 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Simplex-TMR connections

I/O board I/O board

FIELD

I/O board I/O board I/O board I/O board

40 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Simplex-TMR connections

I/O board I/O board

FIELD

I/O board I/O board I/O board IONet (ethernet)

I/O board

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Mark VI – Hardware Simplex – TMR, redundancy and voting process Simplex-TMR connections

Protection Module

x

y

z

V P R O

V P R O

V P R O

IONet Ethernet cables

VME RACK

The three VPRO cards (X, Y, Z) of the emergency rack are connected with the VCMI card of the VME rack (controller) via ethernet cables. The VPRO cards work in close contact with the VME rack for emergency related functions (i.e. overspeed) in order to increase the safety level of the whole control system.

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Mark VI – Hardware Simplex – TMR, redundancy and voting process Simplex-TMR connections

Protection Module

x

y

z

V P R O

V P R O

V P R O

IONet Ethernet cables

VME RACK

R

VME RACK

S

VME RACK

T

43 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Level of redundancy Simplex systems have only one chain, and are the least expensive. Reliability is average.

Simplex systems in a typical power plant are used for applications requiring normal reliability, such as control of auxiliaries and balance of plant (BOP). A single PLC with local and remote I/O might be used in this application. In a typical Mark VI, many of the I/O are non-critical and are installed and configured as simplex. These simplex I/O boards can be mixed with TMR boards in the same interface module.

TMR systems have a very high reliability, and since the voting software is simple, the amount of software required is reasonable. Input sensors can be triplicated, if required.

Triple Modular Redundant (TMR) control systems, such as Mark VI, are used for the demanding turbine control and protection application. Here the highest reliability ensures the minimum plant downtime due to control problems, since the turbine can continue running even with a failed controller or I/O channel. In a TMR system, failures are detected and annunciated, and can be repaired online. This means the turbine protection system can be relied on to be fully operational, if a turbine problem occurs.

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Mark VI – Hardware Simplex – TMR, redundancy and voting process Output processing

Digital output

For normal relay outputs, the three signals feed a voting relay driver, which operates a single relay per signal.

For more critical protective signals, the three signals drive three independent relays with the relay contacts connected in the typical six-contact voting configuration.

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Mark VI – Hardware Simplex – TMR, redundancy and voting process Output processing

Analog output (servo)

For servo outputs as shown in the following figure, the three independent current signals drive a three-coil servo actuator, which adds them by magnetic flux summation. Failure of a servo driver is sensed and a deactivating relay contact is opened. 46 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Input processing

This arrangement is used for noncritical, generic I/O, such as monitoring 4-20 mA inputs, contacts, thermocouples, and RTDs.

This configuration is used for sensors with medium to-high reliability. Three such circuits are needed For three sensors. Typical inputs are 4-20 mA inputs, contacts, thermocouples, and RTDs. 47 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Input processing

Three independent sensors can be brought into the controllers without voting to provide the individual sensor values to the application. Median values can be selected in the controller, if required.

Three sensors, each one fanned and then SIFT-voted. This arrangement provides a high-reliability system for current and contact inputs, and temperature sensors. 48 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Input processing

Speed inputs to high-reliability applications are brought in as dedicated inputs and then SIFTvoted. The following figure shows the configuration. Inputs such as speed control and overspeed are not fanned so there is a complete separation of inputs with no hardware cross-coupling that could propagate a failure. RTDs, thermocouples, contact inputs, and 4-20 mA signals can also be configured this way.

49 13/11/2014

Mark VI – Hardware Simplex – TMR, redundancy and voting process Voting principles

Median Value Analog Voting

0,0,0 → 0 0,1,0 → 0 1,0,0 → 0 1,1,0 → 1

0,0,1 → 0 0,1,1 → 1 1,0,1 → 1 1,1,1 → 1

Two Out of Three Logic Voter

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Mark VI – Hardware VME rack(s) and protection module VME rack cards and relative termination boards

Fiel side devices

Terminal board

VME card

//

//

VCMI

//

//

UCVx

IN contact /OUT relay

TBCI/TRLY

VCCC/VCRC

mA IN (+4 out)

TBAI

VAIC

mA OUT

TBAO

VAOC

TC (thermo-couple)

TBTC

VTCC

RTD

TRTD

VRTD

TURBINE (speed, flame detector...)

TTUR TRPG

VTUR

Regulator (SRV, GCV, LCV, IGV, NZV)

TSVO

VSVO

Vibration sensors

TVIB

VVIB VSCA 51 13/11/2014

Mark VI – Hardware VME rack(s) and protection module VME rack cards and relative termination boards

I/O Card overview Most I/O boards are single width VME boards, of similar design and front cabinet, using the same digital signal processor (TMS320C32). The task scheduler operates at a 1 ms and 5 ms rate to support high-speed analog and discrete inputs. The I/O cards synchronize their input scan to complete a cycle before being read by the VCMI card. Each I/O board contains the required sensor characteristic library, for example thermocouple and resistance temperature devices (RTDs) linearization. Bad sensor data and alarm signal levels, both high and low, are detected and alarmed. Certain I/O boards, such as the servo and turbine board, contain special control functions in firmware. This allows loops, such as the valve position control, to run locally instead of in the controller. Using the I/O boards in this way provides fast response for a number of time critical functions. Servo loops, can be performed in the servo board at 200 times per second.

52 13/11/2014

Mark VI – Hardware VME rack(s) and protection module Protection loop

VPRO Turbine Protection Card

The VPRO card manages the TPRO board in order to control the turbine speed and eventually its syncronization with a power generator. (like the VTUR with the TTUR).

The three solenoids related with the trip condition are managed both from the VTUR (through the TRPG) and the VPRO (through the TREG); if just one requests the tripping, it is implemented.

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Toolbox Toolbox



Introduction



Arrangment • *.m6b structure



Functions • Control functions • Software hierarchy • Validate/build • On line • Download / Compare / Upload • Finder • Watch window • Trend recorder

54 13/11/2014

Toolbox Introduction

toolbox

The toolbox is a software for configuration of various control equipment. Therefore, each product package can consist of the toolbox, product files for the controller or drive, Trend Recorder, Data Historian, and product files for the System Database (SDB). To order the toolbox software and specific product support files.

The Cimplicity is a software for the definition and visualization of the HMI screens for real time control of power-plant, processes and equipment. In addiction, throught the Cimplicity software the operator can issue commands to the selected turbine or driven devices.

cimplicity 55 13/11/2014

Toolbox Arrangement

56 13/11/2014

Toolbox Arrangement *.m6b structure Titlebar

Toolbar

Summary view Idle time Connection / Revision Outline view

Edit status Privilege level

Log view

Status bar

TMR processor connection 57 13/11/2014

Toolbox Arrangement *.m6b structure

58 13/11/2014

Toolbox Arrangement *.m6b structure

59 13/11/2014

Toolbox Functions Control functions

• Load Control • Exhaust Temperature Control

60 13/11/2014

Toolbox Functions Software hierarchy

«@» modules: modification is allowed

«:» modules: modification is not allowed 61 13/11/2014

Toolbox Functions Validate / Build

2

validate

1

Pcode: Pre-compiled code 62 13/11/2014

Toolbox Functions Validate / Build

2

Build

1

in case of errors/warnings, they are listed in the Log view area. 63 13/11/2014

Toolbox Functions On line

2

1

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Toolbox Functions On line

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Toolbox Functions Download and Compare / Upload

Download (application code)

Major and Minor Revision differences are indicated in the Summary View.

If not «equal» a new download is needed 66 13/11/2014

Toolbox Functions Download and Compare / Upload

Download (Application code) 2

1

Download to RAM Download to flash

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Toolbox Functions Download and Compare / Upload

Compare (terminal VME card)

Firmware compatibility check between Toolbox and device

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Toolbox Functions Finder

2

1

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Toolbox Functions Watch window

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Toolbox Functions Trend recorder

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Toolbox Functions Trend recorder

Edit Block Configure

Auto range Upload Pause /Play Recoder

Time axis (range) Remove signal Add signal 72 13/11/2014

Controller - Toolbox - Cimplicity

Controller - Toolbox – Cimplicity •

Toolbox – Cimplicity – controller data sharing • Network layers • TCI (Turbine Control Interface)

•

Cimplicity orrangement • Introduction • Point acquisition check • Properties – measurement units • Screens

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Controller - Toolbox - Cimplicity Controller data sharing Network layers

SupervisorLayer

Control Layer

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Controller - Toolbox - Cimplicity Controller data sharing TCI (Turbine Control Interface)

TCI is part of the Turbine runtime system, which integrates the Mark VI controller, CIMPLICITY HMI, and PI or Historian systems.

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Controller - Toolbox - Cimplicity Cimplicity arrangement Introduction

CIMPLICITY is a very easy-to-use supervisory monitoring and control software product. It consolidates the collection of data from your facility’s sensors and devices,

and then transforms the data into dynamic text, alarm and graphic displays. It gives you access to real-time information, helping you make appropriate decisions to improve quality, productivity and, ultimately, profitability. 76 13/11/2014

Controller - Toolbox - Cimplicity Cimplicity arrangement Introduction

*.gef Workbench project Screens Points Equipment

The Workbench window is divided into two panes. On the left is a folder/file tree that contains the various tools and product options. By clicking on a folder or option on the left, you can view the corresponding configuration items on the right. 77 13/11/2014

Controller - Toolbox - Cimplicity Cimplicity arrangement Point acquisition check

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Controller - Toolbox - Cimplicity Cimplicity arrangement Properties – measurement units

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Controller - Toolbox - Cimplicity Cimplicity arrangement Screens

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Screens and sequences

Screens and Sequences 

Video pages • Video pages



Start-up sequences and permissives • MS5002C start-up sequence • MS5002C shut-down sequence • PGT25+ start-up sequence • PGT25+ shut-down sequence

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Screens and sequences Video pages SCREENS – P&I

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Screens and sequences Video pages

Video pages MS5002C turbine

PGT25+ turbine

SOM6623696

SOM5461132

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L3RF (Ready to fire) L2TVX (ingnition sparks)

Purge (K2TV= 2min) FSR

18% 14%

20%

80% < 60%

88QA = OFF (aux. Pump) 88HQ = OFF (hyd. Pump)

Starting means system OFF (Self substaining speed)

L2VX = 1 (Acceleration)

Warm up (1 min)

20VG (vent valve) CLOSED Ignition (max 10s) FLAME =1

Acceleration to crank (max 2min)

L3ARC Ready to crank (start ing means system )

L1X = 1 (aux. Started)

88QA = ON (aux. Pump) 88HQ = ON (hyd. Pump) 88HR = ON (racket pump) 88BA1/2 = ON (enc. Fan) 88QV =ON (oil separ. Fan)

100%

L3PRC PROCESS/LOAD PREPARATION Pressurization, Encluosure purge, valve position of the load valves

L3ARS Aux ready to start START Command Emergency test (max 30s) L3CRS (core ready to start) L3RS (Ready to start

Screens and sequences Start-up sequence and permissives MS5002C start-up sequence Acceleration to operative speed (max 10min) 92.5%

IGV (from 34° to 56°)

LP speed control

TNH

L14HS = 1 minimum operative speed HP Bleed valves closed.

TNL

LP 45%

L3 = 1 Ready to load

NOTE: The Second Stage variable Nozzels are closed to maintain fixed the HP shaft. time

L4 =1 (master protective signal)

L14LS =1 minimum operative speed LP L14LS → 0 if TNL≤41%

L14HS → 0 if TNH≤90%

NOTE: In case of NO fire after 10s the intersatage vent valve (20VG-1) is re-opened, SRV anf GCV are re-closed. The turbine returns in crank mode. 84

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SRV, GCV closed

Ventilation timer 2h

Lube oil cooler timer Cooldown timer 3h

88QA off 88HR off

88QF off

88BA off

L14HR = 1 and L14LR = 1 +60s delay

Shutdown

STOP condition

Decelerating (max 5min)

stopped

0.1% L14HR = 1 L94X = 0 (SD completed)

Flame

88HR on (rachet)

FLAME = 0

90%

Shut down no flame

100%

L14LR = 1

TNR 50% L14HS = 0

TNR From LP to HP

TNH

unloaded

L94X= 1 (SD in progress) L3 = 0 unloaded

88QA off (aux) 88HQ off (hyd)

L94ASHD

TNL

Shutdown req. HMI, Remote, Aux, Core

Screens and sequences Start-up sequence and permissives MS5002C Shut-down sequence

0.06%

10h

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L3ARS Aux ready to start START request (HMI/Remote) 88BA1/2 on (encl. fan) 88QV on (min. Oil separator)

KHS_CRK_REF

2100rpm

NPTSYNIDL → L3=1, L3ARL

4600rpm (max 1.5min From ignition And Tsynt ≥20°C )

Seal Gas closed (booster stop) AS and Load control active

GTWUDONE = 1 (warmup done) 5min elapsed and Tsynt ≥32°C

Purge 2min

Vibration ON 88CR off

Ignition (max 10s) 28FDX = 1 flame detected

NGG ≥ 1900rpm in max 303s

L3PRC (proc. Valves and seal gas)

Process valves’ sequence start Fuel gas warmup sequence

Proc. Ready to lube (L3PMQA = 1) (seal gas ok)

Emergency test start (L4ETST = 1) ET passed (L3ETP = 1) max 20min

100%

Fuel shut-off valves opened Infravalve vent valve clesed Metering in regulation

88CR on (starting device) Synt. lube oil cooling fans on

L3ARC

Fuel gas OK (P≥20baarg, T≥30°C)

L3ASP L4 = 1

88QA on (aux. pump) F&G N2 bottle bank enabled

L3PRS (process)

Screens and sequences Start-up sequence and permissives PGT25+ start-up sequence WARM-UP

5min 100%

NGGIDL = 6800rpm

6780rpm IDLE SPEED (max 2min from Ignition)

NGG

(max 30min)

Load control 6100rpm

≥ 250rpm If not → NPTBWYFSM = 1 (fail to speen)

NPT

3000rpm

2897.5rpm L14LS=1

time

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Screens and sequences Start-up sequence and permissives PGT25+ Shut-down sequence Syntetic oil cooling timer

IDLE cooldown

5min

2100rpm MOTORING

4h

88BA1/2 off (encl. fan) 88QV off (min. Oil separator) 88QA off (aux. pump) F&G N2 bottle bank disabled

GG cooldown

L14LR = 1 105rpm

L4 = 0 Fuel shut-off valves closed Infravalve vent valve closed Metering valve closed Synt. Oil L, LL disabled Vibration off

L3 =0 (PT unloading)

PT cooldown timer (restart allowed with motoring)

L14HR = 1 300rpm

88CR off (starting device) Clutch disengadged

NGGIDL = 6800rpm

Reload allowed

Shutdown req. HMI, Remote, controller, process

2h

NGG ≤ 300rpm and NPT = 0rpm 88CR on (starting device) Clutch engadged

2745rpm L14LS=0

88BA off (enc. fan)

Off skid fan off Off skid fuelclosed Off skid vent opened

Unit stopped signal to DCS Hot by-pass closed Anti Hydrates closed

NPT

15min

Ventilation timer

L28FDX = 0 (Loss of flame)

6850rpm

Seal Gas opened (booster on) AS and Load control active

NGG

5min

100%

Synt. Oil sep. fan off

time

NOTE: 4h of system lock-out in case of motoring not started in 10min.

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Troubleshooting

Troubleshooting 

Alarms • Alarms in Cimplicity • Alarm from Cimplicity to Toolbox



Data Collection • Alarm History & SOE

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Troubleshooting Alarms Alarms in Cimplicity

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Troubleshooting Alarms Alarms in Cimplicity

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Troubleshooting Alarms Alarms in Cimplicity

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Troubleshooting Alarms Alarms in Cimplicity

Process Alarms : Site specific HMI Panel Text Alarms Events : Each “event” logic signal status change will be printed Diagnostic Alarms : MKVI Panel or System Trouble alarms SOE’s : Digital Signal status message will be printed (Firing, Starting, Accelerating, Warm-Up, Status message, Flame On, etc.) Class ID

Description

Alarmed

Acknoledged

Normal

PRC

Turbine process control alarm (and trip)

PRC Alarm text

PRC Alarm text

PRC Alarm text

DIAG

Signal unhealty and controller faults

DIAG Alarm text

DIAG Alarm text

DIAG Alarm text 92 13/11/2014

Troubleshooting Alarms Alarm from Cimplicity to Toolbox

Take a note of the Alarm ID: i.e P234 Generate an «Alarm List» report from Toolbox 93 13/11/2014

Troubleshooting Alarms Alarm from Cimplicity to Toolbox

Search, in the «Alarm list report», the alarm ID of the alarm to troubleshoot i.e. P234

Under «Signal name» the name of the alarm signal is reported: i.e. L63FGL_ALM 94 13/11/2014

Troubleshooting Alarms Alarm from Cimplicity to Toolbox

Searching the alarm signal is possible to view the logic bloks that manage the alarm, and, as consequence, to understood the possible cause conditions.

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Troubleshooting Data Collection Historical Alarm & SOE

Alarm and Event Report is used to view historical alarms.

Exception Report lists every transition for every alarm and Event. Summary Report list the number of transitions by count for every alarm and event 96 13/11/2014

Troubleshooting Data Collection Historical Alarm & SOE

The Exception Report lists any Alarms, Events, or SOEs, for the period defined and for the Data Types defined.

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Troubleshooting Data Collection Historical Alarm & SOE

The Summary Report lists the number occurrences of each Alarm, Event, or SOE during the period defined and for the Data Types defined.

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