Operability and Lifetime Enhancement with Advanced New

Transcription

Instrumentation & Controls
Operability and Lifetime
Enhancement with Advanced
New Turbine C & I Solutions
Wolfgang Warmuth
Productmanager Turbine Controls
PG L521 – Karlsruhe/GER
Copyright © Siemens AG 2008. All rights reserved
Content
Introduction
Why Investing in a turbine control retrofit ?
Overview
Modernization Concepts
- Governor
Wolfgang Warmuth
Turbine Controls Product Management
- Protection
- Turbine monitoring & diagnostic
Automation system - Hardware
Combined I&C and Hydraulic Upgrade
Siemens Energy Sector
PG L521
Karlsruhe / Germany
- BBC – Bexbach / GER
- SKODA – Kakanji / Serbia
- MHI / WH – Shoubra / Egypt & Tula P.S. / Mexico
- GE Frame – Willmersdorf / GER
Benefits for combined approach
Migration Solutions for TXP and Teleperm ME
Project Execution
Summary
Page 2
SPPA-R3000 Turbine Controls
© Siemens AG 2007. All rights reserved.
Energy Sector
Siemens Power Plant Automation SPPA
Comprehensive solutions with outstanding benefit
Fossil fired
Power Plants
Waste incineration Plants
Fleet Management
Win Power Plants
Combined Cycle
Power Plants
Nuclear Power Plants
Desalination Plants
Industrial Power Plants
Coal Gasification
Plants
District Heat Power Plants
Biomass Power Plants
Page 3
Energy Sector
Solutions for Turbine Modernization
Can I ...
... enhance
the performance
of my old turbines
with new I&C?
Yes you can!
Page 4
Energy Sector
Advanced solutions for all turbines
All types and makes from 1 to 1600 MW
Steam
Turbines
Gas
Turbines
For Siemens turbines
Page 5
Siemens
Westinghouse
Allis Chalmers
Parsons
AEG
Fiat Avio
Alstom/BBC/ABB
Industrial Turbines
For other manufacturer's turbines
LMZ
Skoda
MHI
Alstom/BBC/ABB utility turbines
STC (Shanghai Turbine Works)
GE
Franco Tosi
.... and many others
Energy Sector
Order Split OEM – NonOEM Turbines FY06/07
NON OEM DT;
13.840.000
32%
NON OEM
GT;
22%
10.000.000
OEM GT;
15%
6.700.000
OEM DT;
14.000.000
31%
Advanced Solutions for all types and makes of turbines from 1 to 1600 MW
Page 6
Energy Sector
SPPA-R3000 Turbine Control Solution
Background and Motivation for Modernization of a Steam
Turboset
Why investing in a Turboset?
Wear and tear of originally installed electronic, electrical and related
mechanical components
Spare parts are expensive or no longer available
Extensive overhaul work for the mechanical control and safety
system
► Decreasing In-Market Availability
Changing market requirements ( Derugalation )
Low degree of automation, less operational flexibility
Requirement for a Life Time Extension
► Decreasing Profitability of the Plant
Page 7
Energy Sector
In Market Availability and Operational Flexibility
“In-Market Availability” – is a measure of how successfully a generating plant
captured the revenue earning opportunities in the market over a period of time”
Power Delivery at a required point of time
“Operational Flexibility” – Ability of your power plant to adjust load output
fast and predictable to changing market/dispatch requirements
Page 8
Frequency control and ancillary services
High startup reliability under all turbine conditions
Load change predictability
Controllable load changes and load ramps
Fast start up and shut down
Energy Sector
More plants (mainly older plants)
predicted to be dispatched as
intermediate duty plants
Few plants (mainly new plants with
high efficiency) have the
opportunity to run base loaded
Progressing deregulation of the
power market
Operating hours per year
The Turkish Power Market
New plants operate in base-load regime …
… Implementation of up-to-date technology
results in lowest electricity costs
… while a shift to intermediate load
is expected during lifetime …
… due to competition with new plants.
Lifetime
Potential revenues for increased
flexibility and availability
Therefore advanced solutions for faster starts and
better cycling capability of the power plants necessary
Page 9
Energy Sector
Demand for increased Flexibility and Availability
on demand - Possible Measures
Lifetime Evaluation and
-Extension
Non-destructive Examination
Material Investigations
I&C Upgrades
Operational Flexibility
and In Market Availability
Component Upgrades/
Modernizations
Plant Assessments
Monitoring and Diagnostics
We provide solutions for ageing fleets and changing
market conditions
Page 10
Energy Sector
What limits operational flexibility?
Warm up of main/reheat steam
piping
Limitations on
pressure and
temperature ramp
rates of boiler
drums
HP
bypass
Allowed ramp rates and heat soak times of turbine
components and steam chests
HP
IP
Condenser
LP
bypass
Steam
generator
Deaerator/feedwater
storagetank
HP feed Feed water
water
pump
heater
Main
condensate
pump
LP feed water Condensate
heater
polishing
Low automation level
manual operation required
no coordination of all components and systems
Page 11
LP turbine
Waiting times
for steam purity
Energy Sector
Our solution portfolio
Turbine control master program
Closed loop
Turbine governor
LP bypass control
Gland steam
controller
Boiler feed pump
turbine controls
Coordination
with boiler
Extraction control
Start-up
optimization
Frequency control
acc. to UCTE
Protection
Overspeed
Vibration
Expansion
Axial shaft pos.
Electronic
protection
Manual trip
Open loop
Monitoring
Electrical
Turbine
TSI
oil
supply
Turbine drains
Evacuation
Turning gear
Tappings
Valve test
Generator
controls
etc
Turbine
supervisory
instrumentation
- Diagn. Monitor
Vibration
Expans./ Position
Operation param.
- Analysis
Pressure
Speed
Temperature
Thermal
stress
Dynamic pressure
Generator / unit
/ grid protection
Excitation
systems
Synchronization
Voltage
regulators AVR
Electrical
metering
MV & LV
Switchgears
Uninterruptible
Power Supply
Electro-hydraulical converters, hydraulic / mechanical components
Page 12
Energy Sector
Integrated solutions and approach
Process Engineering Optimizations - the key for success
Consultancy/Engineering
Studies
„Optimize limits“
Instrumentation
& Controls
„Exploit limits“
Component / System
Upgrades
„New limits“
Page 13
Energy Sector
The Turbine Governor
Page 14
Energy Sector
Basic Concept Modernization
Let‘s do it electronically
Protection
Channel 1
Overspeed protection
Protection
Channel 2
Protection
Channel 3
Control
valves
Turbine
governor
E
H
2oo3
Tripping Unit
Stop
valves
Lube oil tank
speed
sensors
Electronic turbine governor (optionally redundant - master/slave)
2oo3 electronic protection with 2oo3 tripping unit
Independent 3-channel electronic over speed trip according to SIL3
Simplified hydraulic only used for valve actuating
- no hydraulic/mechanical governors
- no hydraulic/mechanical protection
Page 15
Energy Sector
Governor upgrade philosophy
Get rid of the complex hydraulic control system
Hydraulic Components
existing
Modern I&C-Systems of SPPA-R3000
new
Speed
Load
Hydraulic Converter
for Speed Control
FD
Pressure
Start-up and
Reference Value Speed Set Point System
Opening
Limiter
SSV
Piston
per
Valve
STV
Page 16
Energy Sector
Modular control structure
Turbine Governor
HP Position Controller
Speed Controller
Load Controller
IP Position Controller
Pressure Controller
Page 17
Speed control
Speed set point
Auto/manual run-up gradients
Thermal stress influence
Acceleration synchronizing
Island mode
Load control
Load set point
Auto/manual load gradients
Thermal stress influence
Load limiters
Frequency influence
Auto load rejection and island
mode supervision
Pressure control
LS-Pressure Controls
LS-Pressure limiters
Position control EHC interface
Position control and supervision
Energy Sector
Benefits of governor upgrade
Optimized and flexible turbine operation
Turbine
Master
Program
Optimized run-up and loading procedures
Thermal stress evaluator influence
Improved HP and IP valve position control
Thermal
Stress
Evaluator
Higher availability
Redundant HW and SW structures
Individual valve control
Turbine
Governor
Monitoring
Stop
Valve
Single
Valve
Control
Control Valve
Page 18
Improved control performance
Flexible adoption of valve opening
sequences
Linearization of valve characteristics
Simple optimization of control loops
Fulfill UCTE requirements
(primary frequency control)
Less mechanical components
Minimized maintenance costs
Reduction of mechanical spare parts
Energy Sector
The Turbine Protection Solution
Page 19
Energy Sector
Plants all over the world expect
maximum security
What we achieve:
1 Security for the machine
(Protection)
2 Security against spurious tripping
(Availability)
3 Security for the environment from the
consequences of machinery failure
(Safety)
The term security will be used here as a collective term for all three of these points
Page 20
Energy Sector
Turbine protection upgrade philosophy
Get rid of the complex hydraulic protection system
Hydraulic Components
Overspeed
Protection
Axial Trust
Protection
Electr. turbine
protection
Condenser Pressure
Protection
Lube Oil Pressure
Protection
Turbine trip system
Page 21
Energy Sector
Typical Electronic Turbine Protection
Speed
(or 1x 2oo3 ?)
Axial Shaft Position
Condenser Pressure
(Turbine and LP Bypass)
Lube Oil Pressure
HP Exhaust Steam Temperature
HP Ventilation
Cold Reheat System Pressure
HP differential Pressure
Bearing Temperature
Diff. res. Bearing Vibration
(existing Measurements)
LP Exhaust Steam Temperature
Page 22
2x 2oo3
1x 2oo3
2x 2oo3
1x 2oo3
1x 2oo3
1x 2oo3
1x 2oo3
1x 2oo3
21x 2oo3
8x 2oo2
2x 2oo3
Energy Sector
Typical Electronic Turbine Protection
Page 23
Condenser Level
2x 2oo3 (LP Bypass)
NDU Water Injection Flow
2x 2oo3 (LP Bypass)
Integration of Fire Protection
binary
Int.Generator Protection
binary
Int. of Boiler Protection
binary
Integration of manual Trip
2x 2oo3 binary
Energy Sector
SPPA-R3000 Electronic turbine protection
The safe solution
Channel 1
Channel 2
Channel 3
Transducer 1
Transducer 2
Transducer 3
I/O
Module
I/O
Module
I/O
Module
Three channel, fail safe principle
from sensor to hydraulic
Equal trip logic in each channel
Additional CPU redundancy
(Master/Slave)
Triple sensors for all important
protection measurements
Independent SIL 3 electronic
overspeed protection
(testable during turbine operation)
3-channel SIL 3 fail safe trip system
2oo3 hydraulic voting
of 3 electronic trip channels
offers online test capability from sensor
to hydraulic of all trip channels
including trip block via incorporated
test program.
Measurement
Redundant
electronic
turbine protection
2 out of 3 Logic
with redundant Automation Server
SIMATIC S7-400H
Output
Module
Speed measurement
Electronic
Trip signals e.g.:
Boiler protection
Gen. protection
Manual trip
3 Channel fail-safe
Turbine trip system
Speed
Sensor
1
Overspeed
Ch. 1
Trip
Ch. 1
Output
Module
Speed
Sensor
2
Overspeed
Ch. 2
Trip
Ch. 2
2 out of 3
hydraulic
turbine trip block
Page 24
Output
Module
Speed
Sensor
3
OverSpeed
Ch. 3
Trip
Ch. 3
Energy Sector
Steam Turbine Protection
Electronic Protection
Redundant Plant Bus Interface
Redundant CPU
ProfiBus DP
Analog / Binary
Sensor Channel 1
F
U
M
F ..
U .
M
F ..
U .
M
I
M
I
M
6
1
6
6
1
6
Red. Cubicle Bus
Red. FUM-Backplane Bus
EU 901
Analog / Binary
Sensor Channel 2
F
U
M
F ..
U .
M
F ..
U .
M
I
M
I
M
6
1
6
6
1
6
2-out-of-3 structure according to
application for:
Sensors
Actuators
EU 901
Analog / Binary
Sensor Channel 3
F
U
M
F ..
U .
M
F ..
U .
M
I
M
I
M
6
1
6
6
1
6
EU 901
Page 25
Energy Sector
Electronic Turbine Protection
SPPA-R3000 Electronic Turbine Protection
Trip Ch. 2
#
Boiler Protec.
Ch. 2
Overspeed
Ch. 3
Protection
System IEC 61508 SIL 3
Page 26
2
3
Trip Signal
Boiler Protec.
#
#
#
LOGIC
„OR“Gate
LOGIC
„OR“Gate
LOGIC
„OR“Gate
Trip Ch. 1
Ch. 1
Boiler Protec.
Manual Trip
Geno Protec.
2
Trip Ch. 3
#
Manual Trip
Geno Protec.
Alarm and Test
Signals
#
Trip Ch. 3
Trip Ch. 2
Manual Trip
Alarm and Test
Signals
Trip Signal
Trip Ch. 1
Geno Protec.
FUM
FUM
Alarm and Test
Signals
FUM
Trip Signal
Speed
Sensor 3
Speed
Sensor 2
Speed
Sensor 1
Transducer
3
Energy Sector
Existing Overspeed Protection System
Mechanical
Overspeed Rings
Mechanical
Overspeed Trip
System
Page 27
Energy Sector
SIL3 electronic overspeed protection
The lifetime extension for your turbine
Fast reaction time (< 10msec)
Multiple set points, alarm and status relays
2 out of 3, 1oo3 & 1oo1 voting logic
Fail safe operation
Manages all fault conditions
Automatic onboard test routine with
integrated diagnostics
Overspeed bolts no longer required
No „real“ overspeed tests necessary
Repeatable and reliable over speed
detection
Avoids unnecessary stress to your turbine
New electronic overspeed protection rack
New speed sensors
Total protection - without compromise
Page 28
Energy Sector
Turbine Trip System FT3000
Page 29
Energy Sector
The Integrated Turbine Monitoring Solution
Page 30
Energy Sector
SPPA-D3000 Machinery Protection and Diagnostic
Turbine Monitoring – Your early warning system
Old Turbines Advanced Flexibility – Advanced Monitoring – Fully Integrated in SPPA-T3000
Unit DCS &
SPPA-R3000
Process
data
Process variables
Machine protection
Protection
SPPA-D3000
Machinery Protection
SPPA-D3000
Machinery Analysis
Turbine generator
Turbine feedwater pump
Protection
Automatic learning for up to 64 operating conditions
Extremely sensitive detection of abnormalities
Outstanding early fault identification
Complete diagnostic tool kit
Page 31
Analysis
Diagnostic
Most
economic
solution
Benefits
Increase availability
Predict and avoid future trouble
Reduce maintenance costs
Energy Sector
Our objective
To obtain full information despite a fault
Classical system
Detect and evaluate
There are four possible faults in
today’s systems that can affect
machine availability:
Profibus
Cable fault
Classical
conversion
Failure of a converter
4... 20 mA
Classical
protection
Failure of a meas. channel
Meas.signal
An additional fault in the second
instrument loop = Shut down machine
Operational
Defective
Page 32
Cable fault
This is where we start!
Signal flow blue signal
Signal flow green signal
Energy Sector
The SPPA-D3000 approach: Improvement
of the system characteristics at these four weak points
Classical system
SPPA-D3000 Machinery Protection
Detect and evaluate
Detect and evaluate
Redundant Profibus
Cable fault
Profibus
Failure
Cable fault
Failure
Classical
conversion
4... 20 mA
Faults that can occur in conventional
systems
Page 33
Each signal via 2 converters
= module redundancy
PCB instead of wiring
Classical
protection
Meas.signal
Operational
Defective
2 x blue signal +
2 x green signal
per line
2 measuring paths per sensor
Measures for avoiding errors in
Signal flow blue signal
Signal flow green signal
Energy Sector
Benefits of protection and monitoring upgrade
Higher safety and availability
Increased safety
with 2 out of 3 protection logics
Optimization of old mechanical protection
loops
Continuous monitoring of sensors
(absence, no coincidence)
Electr. turbine
protection
Turbine trip system
Page 34
Increased availability
Automatic test routines for overspeed
protection loop
Sequential test of all channels
2 out of 3 trip blocks
No limitation of protection status through
test routines
Fewer mechanical components
Minimized maintenance costs
Reduction of mechanical spare parts
Energy Sector
The Hardware Solutions
Page 35
Energy Sector
SPPA-R3000 Turbine controls
Automation system - the cutting edge solution
Hardwired technology
One of the most stable
systems world wide
ISKAMATIC
1970
Page 36
S5 based solution
Well proved
SPPA-R3000
Full integrated
TELEPERM ME,
TELEPERM XP
SPPA-T2000, SPPA-T3000
SIMATIC PCS7 PS
Based on
SIMADYN D, S5 & S5-95F
HW Technology
1985
Based on
S7 Hardware
Technology
2006
Energy Sector
A
!
History of SIEMENS PG L I&C Products
From 1960 to Today
SPPA-T3000
PCS7
TELEPERM XP
SIMATIC S5
µP
TELEPERM ME
BELT- D
ISKAMATIC
IC
TELEPERM C
TRANSIDYN
SIMATIC P
TELEPERM B
Open Loop Control
SIMATIC G
Closed Loop Control
Open Loop and Closed Loop Control
TELEPERM S
1960
Page 37
1970
1980
1990
2000
2005
Energy Sector
The compact high performance automation system
Highlights
Reliable
Meets even the most stringent requirements
for turbine control and protection systems
Scalable
From single-channel to 100% redundancy
for turbine governor (CPU, I/O modules and
communication modules)
Integrated fail-safe application.
Certified to IEC for protection trip
Fast-response
Control circuit for valve positioning integrated
in CPU. Typical cycle time: 6ms
Meets the requirements of UCTE for frequency
support ancillary services
Universal
Only one type of module is used for speed
acquisition, digital data processing and analog
data processing
Page 38
SPPA R3000 – Turbine Governor
Energy Sector
Redundant CPU
Integrated PROFIBUS DP-MasterInterface
Interface to Plant Network
CP
U
FM 400
45 H
8
CP
CPU SIMATIC S7-400H
U
FM 400
45 H
8
S7-400 F/H Turbine Governor and Protection
The fully integrated solution
FM 458 (Function Module)
Top performance for closed loop control
and arithmetic operations
Standard SIMATIC S7-400 Product
Direct Communication with CPU S7-417H
Direct Profibus DP Interface for ADDFEM
communication
AddFEM
(Optimized process interface
for turbine control applications)
Speed
Analog I/Os
Digital I/Os
Page 39
L1+L2+
Governor
2x
2oo3
Protection
#
Overspeed
Protection
ESV/CV Valve
Energy Sector
SPPA-R3000
Function Module S7-400H / FM 458
System Highlights
Leading-edge performance for closedloop control and arithmetic operations
100% redundancy for CPU, I/O modules,
communication modules and bus system
1-out-of-2 logic for controls (hot standby
concept)
Redundant 64 bit RISC floating-point
processor
Extremely short cycle times for CPU
(as short as 0.1 ms)
Position controller: typical cycle time 4 ms
Switchover in < 1 ms on I/O module
fault
Extremely high availability
Supports online reconfiguration
Direct link to plant bus
Page 40
Energy Sector
SPPA-R3000 Highlights
Unique Interface for turbine controls – AddFEM
Optimized single process interface
12 analog inputs (6 can be used as current
inputs and 6 optionally as current or voltage
inputs)
8 analog outputs
12 digital inputs DI / 3 counting pulse
inputs for speed detection
16 digital outputs DO (can also be used
as DI)
In addition to the measuring ranges of
0...20 mA, 4...20 mA and 20 mA common
for current inputs and outputs a range of
50 mA is also available
Analog and digital outputs sustained short
circuits. All outputs monitored, connectable
also in parallel
Time optimized Profibus DP performance
for closed loop control and arithmetic
operations
Redundant configuration possible
Page 41
Energy Sector
More security and availability
with SPPA-D3000 Machinery Protection
Ultra-modern instrumentation
High availability due to
maximum fault tolerance
Integrated bus interface
Fully integrated solution
Protection of the machine
and its environment with
highest possible availability
The safest machinery protection on the world market,
fully embedded in SPPA-T3000
Page 42
Energy Sector
Consistent engineering and uniform HMI
for unit BoP and turbine control
SPPA-T3000 architecture
User
Interfaces
Power
Servers
SPPA-T3000
Application
Server
SPPA-T3000
Automation
Servers
A shared platform:
SPPA-R3000 fully
embedded in SPPA-T3000
SPPA-R3000
Turbine Controls
Process
Interfaces
Page 43
Energy Sector
SPPA-R3000 Turbine Controls can be used in any
plant and operates with any type of I&C equipment.
Turbine Controls
SPPA-R3000 with third-party DCS
HMI & Engineering
HMI & Engineering
Unit I&C
Third-party system
Page 44
Turbine Controls SPPA-R3000
with Siemens DCS
SPPAR3000
Unit I&C
SIMATIC PCS7 PS
SPPA-T2000
SPPA-T3000
Energy Sector
The Hydraulic Solutions
Page 45
Energy Sector
Combine Mechanical with I&C and Electrical Solutions!
Machine
New
Blading
2oo3 Trip
Electronic
Overspeed
Protection
Block
Redesign
Control System
&
Turbine
Single Valve
Control
Upgrades
►
Page 46
Electrical Systems
New
Life Time
Extension
EHCs
Upgrade! No „ONE FOR ONE“ replacement
!
Energy Sector
Do you also know these problems?
1 channel mechanical protection
concepts cause undesired
turbine trips
Frequency control is not possible,
since the turbine's mechanic control
devices are too slow
Valve position control is imprecise
due to mechanical loose
Complex mechanical control valve
constructions are causing high
maintenance and repair costs
Maintenance staff who can carry
out the maintenance at such
complex components is rare and
expensive
Page 47
Energy Sector
References
Bexbach, Germany
OUR Alstom
Solutions
Bexbach / Germany
11 xx 750
750 MW
MW coal
coal fired
fired unit
unit
Page 48
Energy Sector
Bexbach
Key targets
Key Aspects for Turbo Set Modernization
Extensive overhaul work for the mechanical control and safety system
of access
the mechanical
Wear
Difficult
to the tripcomponents
valves in the front bearing pedestal
High requirements to be met by the service personnel carrying out the
overhaul
Less operational flexibility, increasing risk of forced outages through old
control equipment
Increasing availability, reliability and profitability of the plant
Page 49
Energy Sector
Bexbach
One suplier for the complete scope
Automation
Turbine Controller (Speed, Load, Pressure)
Feed Water Pump Turbine Controller
LP Bypass Control and Protection
HP Bypass Control and Protection
Electronic Overspeed Protection
Thermal Stress Evaluation ( Turbomax)
Turbine Supervisory Instrumentation
Control of Turbine Auxiliaries
Mechanic / Hydraulic
Replacement of Overspeed Bolts
Replacement of all mechanic protection devices
Installation of new 2oo3 Trip Block
Single Valve Control for MT and BFPT
Page 50
Energy Sector
Bexbach
Simplification of hydraulic system
Existing hydraulic Control and Protection Concept
Life Steam
Pressure
Limiter
Multiplication
Relay
Vacuum
Limiter
Emergency
Trip
Test MCV
Device
Test
Valve
MSV
Test
Valve
ICV
Operating
Device
Test
Valve
M
Test Valve
Test
Device
ISV
Speed
Governor
Trip
Overspeed
Valve 2
HP
Trips
IP
LP
Emergency
Circuit Sep.
Device
Trip
Valve 1
Safety Relay
Extraction
Check Valve
Page 51
1
2
Protection Channels
Vacuum
Trip
Vacuum
Breaker
Vacuum
Breaking
Device
Energy Sector
Bexbach
Our result – slim, compact and powerful !
New simplified solution:
Overspeed
Trip
Turbine
Controller
Protection
Channel 1
4 x MCV
Protection
Channel 2
40 bar
Protection
Channel 3
Test
Valve
H
E
4 x ICV
H
Test
Valve
E
ISV
MSV
2oo3
Trip Block
IP
HP
LP
Vacuum
Breaker
Vacuum
Breaking
Device
Page 52
Energy Sector
Modernization of BBC GV-Actuator
There was need for new ways…
Main Piston
Facing a lot of Disadvantages:
Complicated hydraulic pilot control
system
Highly complicated hydraulicpneumatical valve testing
Wear in the mechanical feedback
( cams; pinion; gear rack ; etc )
Time consuming overhaul
work necessary
High demands on the service people
Pilot Valve
Page 53
Extensive and time consuming
recommisssioning after overhaul work
Energy Sector
Turbine Governor Upgrade
Detail Concepts – Concept 2
adapter piece
EHC block
Concept 2: Execution example
Complete Modification of the control
valve actuator
Removal of mechanic feedback
One EHC per control valve incl.
mechanic adaptation
(e.g. Siemens ICD - Integrated
Control Device)
Simplification of control oil system
Direct control of the valve position
Page 54
Prop.Valve
Solenoid Valve
Gate Valve
Energy Sector
Bexbach – Modernized ABB AVES Actuator
Old
New
Proportional
valve with
mechanic
modification
Page 55
Energy Sector
Bexbach
Elimination of real overspeed testing
Instalation on existing location at the front bearing and elimination
of mechanical overspeed bolts
Mechanical
Overspeed
removed
Page 56
Energy Sector
Our SKODA
solution
Page 57
Energy Sector
SPPA R 3000 Turbine Control System
Kakanj - Skoda Mechanic/Hydraulic Governor Upgrade
Replacement of hydraulic turbine
controller
Dismantling of several existing hydraulic
components
Assembling of tooth wheel and
sensors for electronic speed
measurement
Proportional
Valve (EHC)
Digital Speed
Measurement
Reproducing controlling algorithms
in the digital turbine controller
Digital Turbine
Controller
Assembling of proportional
Valves (operated by digital turbine
Controller) for operating
control valves
Page 58
Energy Sector
Kakanj - Skoda Mechanic/Hydraulic Governor Upgrade
The solution:
Installation of a new electro-hydraulic
converter (EHC) for pilot control
Characteristics:
New EHC (4..20 mA) replaces the
mechanic control devices
Single or group valve control of the
control valves possible
Control oil pressure of the EHC
operates the control valve's pilot circuit
Position control by using the existing
mechanic feedback
No modification of control performance
Identical Turbine operation mode
Page 59
Control
Valve
Actuator
Electro
Hydraulic
Converter
E
H
Energy Sector
SKODA / Kakanj 7 – New TC Cubicle
Attachment
1
Page
60
Energy Sector
Kakanj 7 – Hydraulic modernization
For information only!
Attachment
1
Page
61
Energy Sector
Kakanj 7 – Hydraulic modernization
New
New Hydraulic
Hydraulic Interface
Interface
Attachment
1
Page
62
Energy Sector
Our MHI
solution
Page 63
Energy Sector
SIEMENS/Westinghouse Electric Corporation
and MHI - Working Relationship
MHI Steam Turbines are build
in 1 to 1 Licence from WH!
1945 to 1979
-
MHI Licensee of Westinghouse
( BB042; BB 044; BB 0243 etc )
1979 to 1989
-
Soft technology transfer (training
of MHI engineering)
1989 to 1993
-
Both parties entitled to pre ‘89 technical
information. Joint development projects
begin.
1993 to 1998
-
Independent development begins,
Compensation for transfer of information.
1998
-
Relationship terminated due to Siemens
acquisition of Westinghouse. © Siemens AG
Page 64
2007. All rights reserved.
Energy Sector
Reference
Reference Shoubra
Shoubra
4 x 350 MW
WH BB 0243-072
Page 65
Energy Sector
Turbine I&C configuration PP Shoubra 4 x 315 MW WH
Turbine I&C
Main Turbine and BFPT
Page 66
Energy Sector
Shoubra – Overview MT Governor Configuration
Page 67
Energy Sector
Reference
Reference Tula
Tula
4 x 300 MW
MHI
MHI Steam
Steam Turbine
Turbine
Page 68
Energy Sector
Scope of Supply for WH Tula ST-modernization
Automation
Turbine Controller (Speed, Load, Pressure)
Turbine Supervisory Instrumentation
Control of Turbine Auxiliaries
Mechanic / Hydraulic
Replacement of all mechanic protection devices
Installation of a new 2oo3 Trip Block
Replacement of Steam chests / Implementation of Single Valve Control
New Servos for Throttle Valves
New Servos for Intercept Valves
Page 69
Energy Sector
Modernization Scope Tula
(WH BB-0243-072 design)
Electro-Hydraulic Actuator Upgrade
Servo actuator assemblies are mounted to existing valve
assemblies
Moog servo valve controls oil flow to and from the turbine valve’s
actuators
Position feed-back provided by new position meaurement (Balluff)
Benefits
Governor speed changer motor headaches resolved
Governor speed changer clutch wear reduced
Valve stroking eased
Maintenance headaches reduced
Page 70
Energy Sector
Modernization Scope Tula
Full EH High Pressure Oil Upgrade
Hydraulic supply system
Plumbing and distribution control manifolds
Servo actuator assemblies
Trip valves per actuator assembly
Benefits
Linear valve movement with no sticking or “dead spots”
Stable, repeatable load control
Reduced maintenance headaches
Easier, smoother valve stroking
Siemens AG
Installed Governor Valve© Actuators
Page 71
(with optional dual trip valves)
Energy Sector
MHI
I&C Systems Refurbishment
New High Pressure Oil Supply Unit
T
Page 72
T
P
Compact dimensions
Latest technology
Permanent Supervision of
Oil pressure
Oil temperature
Oil level
Energy Sector
MHI
New High Pressure Power Actuator
Compact dimensions
Proportional Valve for
fast and precise control
Valve linearization
possible
No leakage or dead time
Compact dimensions
Trip accelerator for fast
turbine trips
NEW
NEW Siemens
Siemens
SPPA
SPPA --R3000
R3000
T
T
P
For information only!
Page 73
Energy Sector
MHI I&C Systems Refurbishment
Full Hydraulic System Conversion
Installation Example
BEFORE
Dir
exis ectly F
ting
it
inst s the
alla
t i on
AFTER
MHI - HP Actuators
Page 74
Energy Sector
SPPA R 3000 Turbine Control Solution
OUR GE Frame Solution
Willmersdorf –
-GE Frame 9
Page 75
Energy Sector
Willmersdorf; 3 x GE Frame 9
Automation
Turbine Control Governor (Replacement of MARK II)
Exhaust Temperature Control
Failsafe Turbine Trip System
Vibration Monitoring
Turbine Auxiliaries
Synchronizing System
Cabling
Page 76
Energy Sector
Page 77
Energy Sector
Page 78
Energy Sector
Page 79
Energy Sector
Page 80
Energy Sector
Page 81
Energy Sector
Benefits
Page 82
Energy Sector
SPPA-R3000 Modernization
Advantages
Reduced maintenance work for the mechanical control system
Reduced mechanical devices and piping
Improved accuracy for turbine control
Lifetime extension of the unit
Improved diagnostics due to electronic systems
Improved availability, reliability and profitability
Page 83
Energy Sector
Only Combined Component and I&C Modernisation
Lever the full Potential of the modernisation
Fuel savings
Higher load output
Lowest lifetime consumption
Heat insulation
Start-up time reduction
Optimized Controls
Permissible Load Ramp
Advanced stress monitoring algorithm,
fully integrated into the turbine governor
for optimal exploitation of the stress
limits, leads in:
Fastest start-up
Optimized Limits
after
before
Measuring insert
+
ϑ(r)
Casing wall
ϑD
r
Tension area
ϑm
-
ϑo Measuring points
ca. 1%
Compression area
Page 84
aprox.
54%
100 %
Time
Energy Sector
Example: Potential Start-up Time Reduction
600 MW Lignite fired Steam Plant
Optimized stress limits,
startup criteria, optimum steam
temperature for unit/boiler control
Floating cold start
criterion
New start up time 1):
New rotor with
optimized geometry
New warm up speed
60%
Start-up time reduction
Supported by advanced turbine and unit controls
1)
From Opening of MS-valves to full load
Maximum Benefit with combined I&C and
Mechanical Upgrade Solution
Page 85
Energy Sector
The Siemens Migration Solutions for TXP
Page 86
Energy Sector
Structure Turbine Controls
Existing Installation S5
based
OM650
Anlagenbus
ES680
DS670
SIMADYN
STRUC G
AS 620B
SIMATIC S5: ZG155 (H)
Interface
SIMADYN D
AS 620B
P C I C
S P MP
U3 5
9 2 3
4 4 0
8
C
P
5
4
3
1
I
M
3
0
8
C
I C
MP
3 1
0 4
4 3
0
P C I
S PM
U3
9 0
4 4
8
CC
PP
5 5
3 4
0 3
1
I
M
3
0
8
C
I C
MP
3 1
0 4
4 3
0
APT
PROFIBUS- DP
SINEC L1
PROFIBUS- DP
AddFEM
AG-F
FUM-B
Page 87
I
M
6
1
4
AS 620T for Turbine
Control (TC)
SIMADYN D & ADDFEM
or SIMADYN I/Os
AS 620F (with AG-F)
SIMATIC S5: AG 95F
for Turbine Trip
AS 620F with APF
and FUM-F
I
M
6
1
4
ET 200M
Energy Sector
Migration Step 1
SPPA-R3000
OM650
ES680
DS670
S7
Engineering
Anlagenbus
Interface
S7- 400/FH mit
FM 458
AS 620B
P C I C
S P MP
U3 5
9 2 3
4 4 0
8
C
P
5
4
3
1
I
M
3
0
8
C
I C
MP
3 1
0 4
4 3
0
P C I
S PM
U3
9 0
4 4
8
CC
PP
5 5
3 4
0 3
1
I
M
3
0
8
C
I C
MP
3 1
0 4
4 3
0
PROFIBUS- DP
replaced
SINEC L1
PROFIBUS- DP
AG-F
I
M
6
1
4
FUM-B
Page 88
I
M
6
1
4
ET 200M
fail-safe
AddFEM
Available
S7 in OM 650 fully
integrated
Interface with TXP via AS
620B for S7 (turbine control
and fail-safe)
Communication AS 620B
with S7 via
Plant Bus
Extended function block
Library within AS 620B
Transfer of S7-Time Stamp
Integrated LT-Diagnose
from S7
HW Engineering S7with S7Tool
(HW configuration)
Common Engineering TXP
and S7 with TEC4function
ET 200M
Energy Sector
Migration Step 2
SPPA-R3000
S7-Manager
TEC- and
HW Config
Engineering
OM650
ES680
Anlagenbus
DS670
T
2
0
0
0
AS 620B
with SIMATIC S7
Available
Fully replacement of S5
Hardware with S7 Hardware
Fully compatible with well
proven TXP SW Packages
S7- 400/FH mit
FM 458
PROFIBUS- DP
PROFIBUS- DP
PROFIBUS- DP
I
M
6
1
4
FUM-B
Page 89
I
M
6
1
4
ET 200M
fail-safe
Integrated
Turbine Control and Failsafe
Turbine Trip S7 based
Common Engineering with
TEC
AddFEM
Extendable
Replacement of S5-based
CPUs AS620B for Turbine
Auxiliaries with S7
Components (T2000)
ET 200M
Energy Sector
Extension of TELEPERM XP Plants
Existing TXP DCS
Extension
with SPPA-T2000
ET
OT
PU-S5
SU
AS 620B
ES
CM
PU-S7
DS
SPPA-R3000
S7-400 FH
FM458
AS 620B
SIMATIC S7
CM-S7
Add
FEM
FUM
FUM
M
M
M
SIM
SIM
M
DP/PA
Link
M
DP/PA
Link
► Protection of your Investment through a homogenous
Extension
© Siemens
AG 2007. All rights reserved.
Page 90
Energy Sector
The Siemens Migration Solutions for TME
Page 91
Energy Sector
Overview: Existing Turbine Control & Protection
Existing Cabinets
Page 92
Energy Sector
Partly Replacement of SIMADYN D and
ISKAMATIC
CJR01
CJP01
CJP02
CJP03
P
R
S
D
E
S
D
N
CXX01
Flame
S
D
TME EHF
TME EHF I/O
TME EHF I/O
TME EA
TME EHF
TME EHF I/O
TME EHF I/O
TME EA
TME EHF
TME EHF I/O
Speed
Speed
S
E
CJQ01
Vibration
Vibration
Fuel Meas.
ISKAMATIC A
TME EHF I/O
TME EA
CJP02
CJP03
T
SPPA-R3000
CJR01
CJP01
F
T
FM-Mod
S74xxH
FM-Mod
TME EHF
TME EHF I/O
TME EHF I/O
TME EA
TME EHF
TME EHF I/O
TME EHF I/O
TME EA
TME EHF
TME EHF I/O
ADD FEM
ADD FEM
ADD FEM
ADD FEM
E
Speed
Speed
U
R
CXX01
Flame
S74xxH
U
CJQ01
Vibration
Vibration
Fuel Meas.
TME EHF I/O
TME EA
?
Page 93
Energy Sector
TME EHF T2000/T3000 FUM
CJR01
CJP01
CJP02
CJP03
P
R
S
D
E
S
D
N
CXX01
Flame
S
D
TME EHF
TME EHF I/O
TME EHF I/O
TME EA
TME EHF
TME EHF I/O
TME EHF I/O
TME EA
TME EHF
TME EHF I/O
Speed
Speed
S
E
CJQ01
Vibration
Vibration
Fuel Meas.
ISKAMATIC A
TME EHF I/O
TME EA
CPA41
CPA01
CPA02
T
SPPA-R3000
CJR01
CJQ01
F
R
E
S7400F/H
Speed E16
I/O Modules
I/O Modules
I/O Modules
Vibration
VM600
I/O Modules
I/O Modules
I/O Modules
I/O Modules
I/O Modules
I/O Modules
BuB + Eng Lats Block G
Vibration
Fuel Meas.
ADD FEM
ADD FEM
ADD FEM
ADD FEM
U
S7400F/H
T
FM458
S7400F/H
FM458
S7400F/H
U
Flame BFI
?
Page 94
Energy Sector
Step1: Extension with SPPA-T2000
Existing
TELEPERM ME
(OMME) DCS
Extension
with SPPA T2000
Web-Client
GET
PU-TME
with HMI-Server
SU
ES
(with GET)
PU-S7
DS
SPPA-R3000
CS 275
S7-400 FH
FM458
AS 620B
SIMATIC S7
AS 220
TME-IO
Add
FEM
FUM
CM
T3000
IEC 60870
Modbus
SIM
M
DP/PA
Link
► Homogenous Extension of TELEPERM ME (OMME)
© Siemens AGPlants
Page 95
Energy Sector
Step 2: Migration OMME into SPPA-T2000
Existing TELEPERM ME
(OMME) DCS
SPPA-T2000
Web-Client
PU-TME
Migration
Teleperm
ME
GET
with HMI-Server
ES
SPPA-T2000
SU
(with GET)
PU-S7
DS
SPPA-R3000
CS 275
AS 220
TME-IO
AS 620B
SIMATIC S7
S7-400 FH
FM458
AS 620B
SIMATIC S7
FUM
Add
FEM
FUM
SIM
CM
T3000
IEC 60870
Modbus
SIM
M
DP/PA
Link
M
DP/PA
Link
Extension
© Siemens
Page 96
Energy Sector
Step 3: Migration T2000 into T3000
SPPA- T2000
Workbench
Thin Clients
Application Server
Web-Client
PU-S7
DS
SPPA-R3000
R3000
Automation
Server
Automation
Server
FUM
CM
T3000
Add
FEM
FUM
SIM
IEC 60870
Modbus
SIM
M
DP/PA
Link
M
DP/PA
Link
Extension
© Siemens
Page 97
Energy Sector
Project Execution
Siemens YOUR Partner during all steps of project execution
Page 98
Energy Sector
Execution process with SPPA-R3000
Joint steps to success
Discussion of
situation
Presentation and
decision
• Operating
experience
• Targets and
options for
modernization
• Result:
Which solutions
are feasible
for this unit?
• Proposal:
Scope of
modernization,
different
variants?
• Benefits?
• Profitability
(return on
investment)?
Implementation
Optimized
operation
• Engineering
• Availability
based on com• Flexibility
prehensive
power plant
• Reduced
know-how
maintenance
• Installation
• Commissioning /
fine-tuning
• Training
• Handover to
customer
Comprehensive
service
concepts
• Corrective
maintenance
• Preventive
maintenance
• Performance
enhancement
• Training &
Consulting
Contract
We never keep you alone!
Page 99
Energy Sector
A
!
Summary
Page 100
Energy Sector
Increased revenues due to improved flexibility
Some References for flexibility
KU Brown – e.on USA
Westinghouse-Steam turbine;
200 MW
Modernization of hydraulic/mechanic interface with
single valve control
Improved dynamics: < 0,5s response time
Improved Acuracy: < 0,5%
Wilmersdorf,
Germany
Gas turbine plant; Alsthom/GE
Frame 9; 3x 90 MW
Benefit for a standard unit
300 MW hard coal fired unit
Change from base load plant to
peak load selling on EEX:
Delta of average price 1) 2) :
13 €/MWh
Revenue: 1,404,000 €/a
Replacement of GE Speedtronic MARK II
Reduced start-up time from 21 min to 7,5 min
Page 101
1)
Source: Actual average values from
EEX; Example 13.12.2006
2) production time per anno 300d x 12h
Energy Sector
Your benefit with SPPA-R3000
Increased performance and reduced costs*
Increased
availability
SPPA-R3000
Turbine Controls
Increased
flexibility
*) During all main operating modes:
Startup Load operation Load ramping
Page 102
Reduced
maintenance
Load rejection
Shutdown
Energy Sector
Your benefits
Improved flexibility
Task
To react flexible on the grid demands and offer
new possibilities on todays energy markets.
Benefits
Improved load flexibility, due to
improved dynamics and island
mode capability
Follow UCTE requirements
Expanded range of economic
operation, due to improved control
accuracy
Improved start-up sequence for
hot stand-by operation and
reduced start-up time
Solution
Replacement of old hydraulic governor with
new redundant electronic control system
Single valve control
Advanced control algorithm
Thermal stress control and supervision
Electronic turbine protection with 3 channel
Central 2oo3 hydraulic trip block;
New HP hydraulic station
New Synchronization equipment
Page 103
Energy Sector
Your benefits
Increased availability
Task
To avoid unnecessary and costly trips of the
unit and to increase lifetime of the turboset.
Solution
New redundant digital governor.
Replacement of mechanical governor and
protection.
Three channel electronic turbine protection
(incl. 3 channel electronic over speed
protection and fully integrated fail safe
turbine trip system).
Replacement of mechanical protection.
New hydraulic interface with 2oo3 hydraulic
trip block and single valve control.
New field instrumentation
Turbine supervisory instrumentation
(TSI equipment)
Standardized and proven I&C-systems.
Redundancy concept:
From sensors up to HMI
Page 104
Benefits
Minimization of forced
outages
Reduction of lifetime
consumption
Lifetime extension of the
plant
No real overspeed tests
necessary
Energy Sector
Your benefits
Reduced maintenance costs
Task
Reduce costly efforts for maintaining and
fault finding.
Solution
Replacement and elimination of
hydraulic/mechanic protection system
Three channel electronic turbine
protection
(incl. 3 channel electronic over speed
protection and fully integrated fail safe
turbine trip system)
New digital electronic governor
New turbine supervisory system (TSI)
Increased automation level
Modernization of field equipment
Page 105
Benefit
Advanced I&C diagnostics
Advanced operational supervision
Reduced maintenance for mechanical
and electrical components
Automatic tests during operation
Energy Sector
SPPA-R3000 Turbine I&C Modernization
Detail Concepts – Overview
The suitable solution for each demand and each budget
Special solution desired?
New high pressure hydraulic
Complete exchange of turbine hydraulic
Frequency control
Increase of control performance
Modification of valve actuators
Reduction of mechanic devices
Installation of hydraulic
standard interface
Page 106
Energy Sector
Summary
Proven Technology SPPA-R3000
Standardized
Scalable
Extendible
SPPA-R3000 Integrated Solution into Plant DCS
(TXP; T2000; T3000; PCS 7 )
Common HMI
Engineering Environment
Homogenous Extension and Migration Concepts for
TELEPERM ME
TELEPERM XP
to SPPA-T2000 und T3000 Power Plant Automation System
► Safe Investment for Future Plant Operation
Page 107
Energy Sector
Extract of References
1. BEWAG Berlin Oberhavel, Germany – 1x 110 MW AEG Steam Turbine (1999)
2. EWAG Nürnberg, Germany – 2x 45 MW AEG Steam Turbine (2002)
3. Cairo South, Egypt – 1x 70 MW AEG Steam Turbine (2000)
4. Elverlingsen 3, Germany – 1x 250 MW AEG Steam Turbine (1998)
5. EON, Arzberg, Germany – 1x 1300 MW AEG Steam Turbine (1998)
6. Peterhead, UK – 1 x 660 MW GEC-Alstom Steam Turbine (2000)
7. Barking Power; UK– 1 x 215 MW GEC-Alstom (2005)
8. Barking Power; UK– 1 x 145 MW GEC-Alstom (2006)
9. ERC; Nikola Tesla ; Serbia 1 x 300 MW MAN-Alstom (2002)
10. Gelderland ; Netherland 1x 605 MW MAN-Alstom Turbine (2004)
11. EVN Dürnrohr, Austria – 1x 300 MW MAN-Alstom Turbine (2007)
12. Electrabel; Bergum; Netherland 1 Unit – 1x300 MW MAN-Alstom Turbine (2007)
13. Eskom Camden Power Station 8 Units – 8 x 200 MW Parsons (2004)
14. ENBW Germany RDK 1 Unit – 1 x 550 MW BBC Reheat Turbine (2005)
15. E2 Denmark; Kyndyvaerket 2 Units – 2 x 260 MW BBC Turbine (2005)
16. Saar Energy. Germany 1 Unit - 1 x 750 MW BBC Reheat Turbine (2004)
17. ESB Ireland, Moneypoint - 3 x 350 MW BBC Reheat Steam Turbine (2005)
18. Bosnia, Kakanj 7; 1x 230 MW Skoda Turbine (2005)
19. CFE ; Mexiko; Tula 3 & 4; 2x 350 MHI Steam Turbine (2005)
20. CFE ; Mexico; Manzanillo 1&2; 2x 350 MW GE Steam Turbine (2004)
21. CFE ; Mexico; Salmanca Unit 3; 1x 300 MW Franco Tosi Steam Turbina (2005)
22. ELSAM Denmark; Studstrup Vaerket 2 x 350 MW BBC Steam Turbine (2003 )
23. ENBW Germany; Altbach 1 x 450 Reheat Siemens Steam Turbine (2005)
24. Kentucky Utility; USA 1x 200 MW Westinghouse Steam Turbine (2002)
25. Stadtwerke Munich, HKW Nord – 1 x 30 MW BBC SteamTurbine (2006)
26. Morupule, Botswana – 3x 33 MW Parsons Steam Turbine (2006)
27.
Morupule,
Botswana
–
1x
33
MW
Toshiba
Steam
Turbine
(2007)
…….
And many more
!!!
Page 108
Energy Sector
Turbine I&C systems
Multiple Challenges around the turbine - We cover it all !
Load
Setpoint
Actual
Load
Vibration Monitoring Speed Governor
Circuit
Breaker
Casing Temperature
Data
Monitoring
Logger
Water
Injector
Speed
Measurement
Page 109
Oil
Supplier
Protector
Energy Sector
Published by and Copyright 2008:
Siemens AG
Energy Sector
Fossil Power Generation
Siemensallee 84
D-76187 Karlsruhe
Phone: + 49 7 21 / 5 95 - 69 43
Fax: + 49 7 21 / 5 95 - 67 21
E-Mail: sppa-r3000.pg@siemens.com
www.siemens.com/sppa-r3000
Subject to change without prior notice.
The information in this document contains
general descriptions of the technical options
available which do not always have to be
present in individual cases.
The required features should therefore be
specified in each individual case at the time
of closing the contact.
For further information by e-mail please contact
SPPA-R3000.pg@siemens.com
This document contains forward-looking statements and information – that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of
similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results
and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others,
from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide,
changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on the SEC’s website, www.sec.gov. Should one or more of
these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend
or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated.
Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.
Page 110
Energy Sector

Operability and Lifetime Enhancement with Advanced New

Transcription

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