Вы находитесь на странице: 1из 99

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

2
13/11/2014

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

5
13/11/2014

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

8
13/11/2014

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

10
13/11/2014

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

11
13/11/2014

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

Cooling
12:
23:
34:
41:

Isentropic Compression
Constant pressure Heating
Isentropic Expansion
Constant pressure Cooling

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 systems 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

Useful Specific Work is:


Wout = Wexp Wcomp
where:
Wexp = h3 h4 = cp ( T3 T4 )
Wcomp = h2 h1 = cp ( T2 T1 )

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:


=
=


=1
=
=

Therefore, id is only dependant on:


the pressure ratio ( = p2 / p1 )
the nature of gas ()
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 id can be plotted as functions of :

Wmax

15
13/11/2014

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.

1
Compression

Cooling

4
Cooling

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

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

Qf
4
2

2
4

Wc

Wt

Qexh

1
S

Wt < Wexp
Wc > Wcomp
Wc

= cpm1-2 (T2 - T1)

[Kj/Kgair]

Wt

= cpm3-4 (T3 - T4)

[Kj/Kggas]

Qf

= cpm2-3 (T3 - T2)

[Kj/Kggas]

Qexh = cpm4-1 (T4 - T1)

[Kj/Kggas]

=1

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

T
fuel
CC
2

Exhaust
3

Qf
4

2
2

Wc

Wt

Qexh

1
S

The Useful Power (Shaft Power) is defined as:


Pu = Ggas Wt - Gair Wc
[ 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, Wout and are here plotted as functions of :

Increasing the pressure ratio , while W has


almost the same behavior as in the ideal
case, the efficiency increases up to its
highest value and then decreases.

1 matches to the maximum work, but


it relates to a poor efficiency

2 corresponds to the highest


efficiency, but a lower work is delivered
to the load

19
13/11/2014

Turbine and Auxiliaries Gas Turbine review and working principles


Brayton Cycle

Air
Intake
1

fuel

Exhaust
CC

3
4

Qf

Wt

2
C

2
Wc

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 (=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

21
13/11/2014

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).

25
13/11/2014

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 of this vane
its 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

28
13/11/2014

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

29
13/11/2014

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

32
13/11/2014

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

34
13/11/2014

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

35
13/11/2014

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.

36
13/11/2014

Mark VI Hardware Panel introduction


Simplex

Main parts

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

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

41
13/11/2014

Mark VI Hardware Simplex TMR, redundancy and voting process


Simplex-TMR connections

Protection Module

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.

42
13/11/2014

Mark VI Hardware Simplex TMR, redundancy and voting process


Simplex-TMR connections

Protection Module

V
P
R
O

V
P
R
O

V
P
R
O

IONet
Ethernet cables

VME RACK

VME RACK

VME RACK

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.

44
13/11/2014

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.

45
13/11/2014

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

50
13/11/2014

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.

53
13/11/2014

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

validate

Pcode: Pre-compiled code


62
13/11/2014

Toolbox Functions
Validate / Build

Build

in case of errors/warnings, they are listed in the Log view area.


63
13/11/2014

Toolbox Functions
On line

64
13/11/2014

Toolbox Functions
On line

65
13/11/2014

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

Download to RAM
Download to flash

67
13/11/2014

Toolbox Functions
Download and Compare / Upload

Compare (terminal VME card)

Firmware compatibility check


between Toolbox and device

68
13/11/2014

Toolbox Functions
Finder

69
13/11/2014

Toolbox Functions
Watch window

70
13/11/2014

Toolbox Functions
Trend recorder

71
13/11/2014

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

73
13/11/2014

Controller - Toolbox - Cimplicity Controller data sharing


Network layers

SupervisorLayer

Control Layer

74
13/11/2014

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.

75
13/11/2014

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 facilitys
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

78
13/11/2014

Controller - Toolbox - Cimplicity Cimplicity arrangement


Properties measurement units

79
13/11/2014

Controller - Toolbox - Cimplicity Cimplicity arrangement


Screens

80
13/11/2014

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

81
13/11/2014

Screens and sequences Video pages


SCREENS P&I

82
13/11/2014

Screens and sequences Video pages

Video pages
MS5002C turbine

PGT25+ turbine

SOM6623696

SOM5461132

83
13/11/2014

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 TNL41%

L14HS 0 if TNH90%

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

13/11/2014

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

85

13/11/2014

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 20C )

Seal Gas closed (booster stop)


AS and Load control active

GTWUDONE = 1 (warmup done)


5min elapsed and Tsynt 32C

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 (P20baarg, T30C)

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

86

13/11/2014

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.

87
13/11/2014

Troubleshooting

Troubleshooting

Alarms

Alarms in Cimplicity

Alarm from Cimplicity to Toolbox

Data Collection

Alarm History & SOE

88
13/11/2014

Troubleshooting Alarms
Alarms in Cimplicity

89
13/11/2014

Troubleshooting Alarms
Alarms in Cimplicity

90
13/11/2014

Troubleshooting Alarms
Alarms in Cimplicity

91
13/11/2014

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
SOEs : 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.

95
13/11/2014

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.

97
13/11/2014

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.

98
13/11/2014

99
13/11/2014