KELI 2008

Field Report :
Control System ME 4012 for
gas turbine A (93.0 V) at unit 4
Power plant Altbach / Deizisau

EnBW Helmut Mauell GmbH

Elektro-/ Leittechnik Dipl. Ing. Detlef Baran Energy
Dipl. Ing. David Maier dba@mauell.com
da.maier@enbw.com +49 2053 - 13 478 needs Impulses
+49 7153 602 - 55 24 0

06th of Mai 2008

 Table of contents

1. Tasks of the new Gas Turbine Control System ME 4012 slide 3. Achieved objectives and operational experience: slide
Control System replacement of gas turbine A
• Principle of process Combined Cycle Unit 4 3
• Turbine behavior during start-up and load operation 21
• ME-VIEW scheme of control loops and functional groups 4
• ME4012 System overview Unit 4, Altbach / Deizisau 22
• Air system and combustion process of the gas turbine 5
• Control System characteristics 23
• Air / exhaust gas of the gas turbine 6
• Contract Award 24
• Ignitiongas and naturalgas system 7
• Planning and Manufacturing 24
• Heating oil system of gas turbine
(Draft sketch according to VGB R 170 C) 8 • 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

2. Solution: Functions and Control Strategy 5. Reference List Process Control System ME4012:
Gas turbines and Combined Cycle Plants 28
• 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

2 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:
Principle of process Combined Cycle Unit 4

Flue gas
Steam power Injection

Boiler
drum

200MW Water
pipes

Steam turbine

Gas
Sek. - Prim.

Oil
superheater

Oil
Fire Area
Gas Feed water flow

M Burner

Compressor
Cooler
Turbine

Demineralize

50MW Oil
Gas

Combustion
M chamber

3 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:
ME-VIEW scheme of control loops and functional groups

Übersicht des Lieferumfanges

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:
air system and combustion process of the gas turbine

5 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:
Air / exhaust gas of the gas turbine

6 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:
Ignitiongas and naturalgas system

Automatic switch over of operation modes:

Diffusion to pre mixed operation

7 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:
Heating Oil system of gas turbine (draft sketch according to R170C)

8 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:
Deionized water injection for NOx reduction during oil operation

9 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:
Auxiliary oil / lube oil system of the gas turbine

Turning gear
(Hydro motor)

10 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:
Turbine Protection System (Turbine surveillance supervision)

11 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:
Electrical Integration

12 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 2. Solution: Functions and Control Strategy
Speed-, power-, frequency- and temperature-control

Slave (full interface and processing redundancy)

Ramp Setpoint
function Mode of Frequency Exhaust deionized water
Synchronizer
generator operation temperature injection

Speed Power Temperatur-

setpoint setpoint Setpoint sollwert Setpoint Deionized
Setpoint generation generation water injection
generator speed power temperature (Oil > 25MW)

Turbine Electrical Exhaust Flow

speed Speed power Power temp. Temperature
controller controller controller
controller
Deionized water

Coordinator

Master
Valve
position > 25MW asynchronous balanced mode
controller

Oil-ESV Oil-CV Gas-CV Gas-ESV

M
F
Compressor M
P Turbine T Deionized
n water- CV

50MW M

13 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 2. Solution: Functions and Control Strategy:
Speed-, power-, frequency-, temperature- and fuel-control
100%
Start up
setpoint
60% diagram

15%

0 T
300°C 396°C
C°
Synchronisation
Ramp function
generator Synchronizer

Speed
setpoint Setpoint Speed
generator speed controller
Oil
flow
Turbine EHC-
speed position

Fuel Flow Valve position EHC-position

Operational Frequency
controller controller controller
mode

Oil-CV
Power position
setpoint Coordinator Setpoint
Setpoint Power i

(bumpless generation
control power controller
switch) amount of fuel
EHC-
position
Electrical Flow Valve position EHC-position
power Shares plate controller
Exhaust controller controller
temperature Gas / Oil and
automatic fuel
switching, Gas-CV-
Temperature Base: position
Setpoint Energy content /
setpoint Temperature
control heat balance Gas
temperature controller flow

Exhaust
temperature

Deionized water injection for Deionized

water flow

NOx reduction in oil operation Fuel

Electrical
power Setpoint Valve
Flow Power
generation position
controller adjuster
deionized water controller

Mode of operation Deionized water M

CV-position

14 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Turbine controller (1oo2), Turbine protection (2oo3, SIL3)
Master
Diagnostics and
Turbine Governor Channel A
CPU Documentation Operator station

Alarms, SOE,
Analog Protocol
output ME-DRP ME-VIEW
AE4012

Binary
output LAN
SUB-NET
Analog
input

Pulse
input

Life trip system

Channel 1 1

Life trip system

Channel 2 Pulse
pre-amplifier
Pulse and decoupling
input
1 Over speed
Turbine Governor Channel B

protection
Analog (2 oo3) SIL 3
output 3
GT
AE4012

Binary 2 oo3
output
E/H-Converter
Servodrive
Servodrive Time critical Realtime funktions
Analog realtime funktions CPU-Functional Area 2
input CPU-Functional Area 1 < 10ms
< 4 ms Funktion group controls
Oil-ESV Öl-CV Speed control setpoint Power control setpoint
CPU Speed controller Power controller
Slave E/H-Converter Acceleration Measurement Frequency influence
Servodrive
Servodrive Fuel valve position controller Flue gas temp. controller
Fuel controller
Life trip system Combustion controller
Channel 3 3
Gas-ESV Gas-CV Deionized water injection
Anti surge control
AE4012
Turbine protection 2 oo 3
15 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 2. Solution: Functions and Control Strategy
Turbine speed measurement for controller and
fail-safe (SIL 3) overspeed protection

Turbine
Pulse pre-amplifier overspeed
protection 2oo3
Channel 1 SIL3

IE2FZ

2 oo 3
Channel 2

&
Turbine IE2FZ

shaft Channel 3
DW channel 1 Emergency
IE2FZ DW channel 2 shut off valve
DW channel 3
Reserve
detector
IE2 FZ
Turbine
speed
measurement
1oo2

ME4012 Processinterface I/O- Bus

Digital speed measurement :

Accuracy : 0,004 % = +/- 2mHz at 50 Hz netw. frequency

SUB-NET
Speed and
Signal resolution : 0,5 mHz power controller
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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Gasturbine protection: Overview machine protection
Generator Life trip system 2 oo 3 Failsafe trip system 2 oo 3, SIL 3
protection Electrical and mechanical trip criterions Overspeed protection

+L1 +L2

# #

Turbine controller Turbine controller

(Master) (Slave)
Channel 1 1 Channel 2 1 Channel 3 1
+L3
SUB-NET
Life trip system

Life trip signal tranfered as Failsafe trip signal

# Criterion permutation

Quarz Quarz Quarz

comparator DW DW DW comparator DW DW DW comparator DW DW DW
Test program Failsafe
Fuel control valve overspeed fuel
detector protection

FST

FST

FST

FST

FST

FST

FST

FST

FST
system

LT

LT

LT

LT

LT

LT

LT

LT

LT
(2 oo 3)
& & & & & &
t0 2 oo 3 t0 2 oo 3
& &
Function group T.-protection latch
Turbine control >3 turns min-1
24V +L1
24V +L2
24V +L3 Turbine protection Failsafe Failsafe Failsafe
trip trip trip
manual trip (2 oo 3) module
module module
LSN24 DW-Modul 1 # DW-Modul 2 # DW-Modul 3 #
emergency stop
(Turbine trip)
Test program
hydraulic trip Fail-Safe 2 v 3 (EAM)
block

Control oil
Hydraulic trip Seat Seat
block 1 oo 2 valve valve

Pi
Turbine hydraulic
system
17 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 2. Solution: Functions and Control Strategy
Gasturbine protection: Overview fuel trip system

Life trip system 2 oo 3 Overspeed protection

Turbine controller 1v2 2 oo 3 (SIL 3) Turbine
shaft

Hydraulic Control oil

trip block 1 oo 2
Fail-Safe 2oo3
shut off valve
Fail-Safe fuel trip (SIL3)

> 60% Load

asynchronous Seat
M balanced valve
operating low NOx

Fuel M < 60% Load Fuel CV ESV 1 ESV 2

diffusion
Burner operating
M

Pilot flame
2. Shut-off 1. Shut-off

Propane
Ignitor
valve valve

gas
Pilot light

Combustion chamber Venting system

18 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
2. Solution: Functions and Control Strategy
Operator system ME VIEW and location involvement
Controlroom Unit4 Controlroom HKW 2 Relay room HKW 2
GT-A

ME-DRP
ME-VIEW ME-VIEW ME-VIEW Balance ME-AIS ME-DRP Server /
Client Client Client protocol Client Client

VIEW-LAN

VIEW-Switch 1 VIEW-Switch 2 Documentation

VGB standard R 170 C

EnBW On-line features:

Management system -- Diagnosis
Router -- Configuration
PI-System
-- Simulation

RAID RAID
Gateway 5 5
PC
DRP-
PD-Switch 1 Switch PD-Switch 2
(Rail)

Distributed coupling ME4012 Distributed coupling ME4012

DRP-LAN

19 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 2. Solution: Functions and Control Strategy
Automation Unit AE 4012 and location involvement
PD-Switch 1 PD-Switch 2

SUB-NET Level B

Automation Automation Automation

SUB-NET SUB-NET SUB-NET SUB-NET
Coupler Coupler
unit UVIEW unit UVIEW
Coupler Coupler
unit
AE 4012 AE 4012 AE 4012

SUB-NET Level A

TC 1 Multi- TC 2 Multi- TP 3 Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi- Multi-
TP 1 functions- TP 2 functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions- functions-
processor processor processor processor processor processor processor processor processor processor processor processor processor processor processor processor

Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog- Binary- Analog-
Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/ Input/
Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output Output

marshalling rack marshalling rack marshalling rack

~ ~ ~

Auxiliary Fail-Safe Power

cabinet System adjuster
Flame / Fail-Safe Stepping
burner logic control drives
surveillance

Shaft Turbine Stepping

vibration protection control drives
measurement

Coupling Burner Stepping

relays protection control drives

~ ~ ~

Gas turbine Steam generator Hardware signal exchanges:

- Control steam generators
Turbine controller, Turbine protection Turbine, burner, flue gas flap auxiliary power - Daily oil tank
- Operating load distribution
- start-up device /
alternator excitation

20 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 3. Achieved objectives and operational experience
ME4012 System overview Unit 4, Altbach / Deizisau
Control Room Unit 4 Control Room Unit 2 Relay Room Unit 2
EMI ME-AIS

Alarms Client Client Balance protocol: Client ME-DRP ME-DRP

- Performance Client Server
- Work
- Operating Hours
Client - Consumption Projekt
Documentation
- Cooling water diary Diagnosis database

250m
30 m
30m

LWL

Splicebox
PI-System
Router
Environment LWK
Office Railswitch
Server 1 Server 2 Gateway
PC

USV USV
Flue gas
emission Fibre optic cable (FOC)
Computer Electronic Room
Hardwired Signals
Unit 2 9,5 m

SUBNET B-Level

Relay-Room Unit 4 FOC

(200 MW ST / 50 MW GT) 250 m FOC 250 m
Switch

SUBNET A-Level

SN
CAN
CAN-Bus only for cabinet internal surveillance

Hardwired signal exchanges:

AE4012 AE4012 ME4002S Auxiliary Cabinet AE4012 - Control steam generators

Power adjuster - Daily oil tank
Turbine protection Turbine burner Fail-Safe logic Stepping control drives Flame burner surveillance Steam Generator
Turbine controller Exhaust flap Turbine protection Burner surveillance Auxiliary power - Operating load distribution
Burner protection Shaft vibration measurement - Start up device / alternator excitation
Coupling relays
22 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 3. Achieved objectives and operational experience
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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience
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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience
in the power plant Altbach / Deizisau

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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
3. Achieved objectives and operational experience
in the power plant Altbach / Deizisau

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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 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 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 Reference List Process Control System ME4012:
Gasturbines and Combined Cycle Plants
Manufacturer Steam turbine /
No. Plant Operator Country Function
DT / GT Gas turbine
1 HKW Halle / Trotha D Siemens / Siemens 60 MW / Serial integration of GT-
Siemens V64.3 25 MW and DT-control system in
the Process Control
System ME 4012
2 Stadtwerke Munich D Siemens / Siemens 105 MW / Plant Control System
Heizkraftwerk Süd Siemens V94.1 2x 100 MW ME 4012 for control and
Combined Cycle 1 protection
3 Stadtwerke Munich D ALSTOM Power / 140 MW / Plant Control System
Heizkraftwerk Süd ME 4012 for control and
Combined Cycle 2 protection
General Electric 2x 140 MW Integration of process-bus
Frame 9E into Mark 5-GT-control
system
4 EnBW PP Altbach / D Siemens V93.0 50 MW Plant Control System
Deizisau, GT-A ME 4012 for control and
protection
5 Industry Power Plant D Ruston Tornado 6,3 MW Hard-wired interfacing to
Carl Freudenberg, Unit Control System
Weinheim, GT1 Boiler 4
6 Industry Power Plant D Turbomach 5,5 MW Hard-wired interfacing to
Carl Freudenberg, Caterpillar, Taurus Unit Control System
Weinheim, GT2 Taurus T60 Boiler 5
28 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008
 Energy
needs Impulses

A01.4012.11E08
29 David Maier / Detlef Baran KELI 08: Digital Control System ME4012 for gas turbines 06th of Mai 2008