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POWER PLANT DCS traning of MHI.APPDCLLNT power projectConfidential doc
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© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.
Training for Steam Turbine Control
Krishnapatnam Thermal Power Project, 2 X 800 MW
22 May. 2013
NAGASAKI CONTROL SOLUTIONS SECTION
INSTRUCTOR: AKIRA ISHIGAKI
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2
1. SYSTEM CONFIGURATION
2. TURBINE CONTROL SYSTEM (TCS)
3. TURBINE AUXILIARY EQUIPMENT CONTROL
4. TURBINE PROTECTION SYSTEM (TPS)
5. TURBINE SUPERVISORY INSTRUMENTS (TSI)
6. ATS (Automatic Turbine Start-up)
7. TURBINE SHUT-DOWN
Contents
Contents
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 3
1. SYSTEM CONFIGURATION
1. SYSTEM CONFIGURATION
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 4
1. SYSTEM CONFIGURATION
Abbreviations
System Configuration
Abstract of System Configuration
Network Interface
Functional Overview
System Configuration
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 5
1. SYSTEM CONFIGURATION
OPS : Operator Station ACS : Accessory Station (For Trend-data archive) EMS : Engineering & Maintenance Station MPS : Multiple Process Station OPC Server : OLE (Object Linking & Embedding) for Process Control HDS : Historical Data Server TSI : Turbine Supervisory Instrument TPS : Turbine Protection System TCS : Turbine Control system
ABBREVIATIONS
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 6
1. SYSTEM CONFIGURATION OPS
EMS
ACS
TCS TSI TPS
Data Collection System
OPC Server
HDS
MPS MPS MPS MPS
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 7
Abstract of System Configuration
OPS ACS
EMS MPS
Ethernet (100Base-Tx)
Control Net
I/O Adapter
TCS
Local Instruments
1. SYSTEM CONFIGURATION
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 8
Network Interface
EMS/OPS/ ACS
Control-Net (5 Mbps)
A B
System I/O Interface
System I/O Interface
CPU-A
CPU-B
Ethernet-A1 Ethernet-A2
Ethernet-B1 Ethernet-B2
HUB
HUB
A
Local Network Interface
B Network Adapter I/O Module
A B
Network Adapter I/O Module
PT TE Valve
Local
A B
Local Network Interface
1-2. SYSTEM CONFIGURATION
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 9
Sample: CPU Chassis
9
System DIO
Control Net EthernetA-1/2
CPU Power Supply-1/2
A B
CPU-A
Sample
1-2. SYSTEM CONFIGURATION
Human-machine interface for plant operation and monitoring.
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 10
1. SYSTEM CONFIGURATION
Operator Station (OPS)
FUNCTIONAL OVERVIEW
Engineering tool for performing system configuration, creation and modification of control logic, graphic displays, trends and control loop plates.
Engineering & Maintenance Station (EMS)
Digital controller used to perform automatic turbine control and protection and features advance capabilities that support high-speed processing such as Turbine governor control and protection interlocks.
Multiple Process Station (MPS)
Storage for long-term data archives.
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 11
1. SYSTEM CONFIGURATION
Historical Data Server (HDS)
PC for data storage into media devices. Data Management System
For communication interface between TCS and Plant-DCS. OLE for Process Control (OPC) Server
FUNCTIONAL OVERVIEW
Performs data logging and data archives such alarms, events and trend graphs.
Accessory Station (ACS)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 12
2. TURBINE CONTROL SYSTEM
2. TURBINE CONTROL SYSTEM (TCS)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 13
2. TURBINE CONTROL SYSTEM
TCS Control Area
TCS Special Function Modules
Relation between TCS Special Function Modules
TCS Control Functions
Turbine Control System (TCS)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 14
2. TURBINE CONTROL SYSTEM TCS Control Area MSV, GV, RSV and ICV are controlled in TCS for: Turbine Speed Control APC Link (Load Control by Turbine Master)
HP/IP LP
Cross Over Piping
HRH (LH)
HRH (RH)
MS (RH)
MS (LH)
RSV
RSV
ICV
ICV
MSV
MSV GV
GV
Governor Valves controlled by TCS
ICV
ICV
GV
GV
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 15
2. TURBINE CONTROL SYSTEM
TCS Special Function Modules
EOST (Electrical Over Speed Trip detection) Module Speed detection for Turbine speed control EOST (Electrical Over Speed Trip:111%) detection
OPC (Over speed Protection Controller) Module OPC detection (Combined Curve)
TCL (Turbine valves Closing Logic) Module Closing turbine valves with fast speed Interface with SVL and OPC modules
Following Special Function Modules are equipped in TCS cabinet :
SVL (Servo Valve interface (LVDT feedback) ) Module Send electrical signal to Servo Valve Receive LVDT position signal as feedback.
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 16
2. TURBINE CONTROL SYSTEM
Valve Demand
TCS Hardware
P T
0%
Local
High Press. Oil
Position Feedback Signal
(0~100%)
Governor Valve
TCS Software Logic
Position Feedback
Forced Close
Command (From TCL
Module)
Software Signal 0~100%
Valve Demand -50~+50mA
LVDT Signal (Voltage)
Servo Valve
LVDT Δ
-
+
TCS Special Function Module: SVL Module Electric signal from TCS (SVL module) is converted to Hydraulic signal by Servo Valve
Linear Variable Differential Transformer
SVL Module
LVDT Interface
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 17
2. TURBINE CONTROL SYSTEM
SVL (A)
SVL (B)
Double Redundant SVL module applied to each Servo Valve.
Reference:
Detailed Schematic Diagram is available in Drawing No. 66400-7021 “Schematic Diagram For TCS And Turbine Communication Equipment Cabinet”.
SVL (A)
SVL (B)
Servo Valve
Schematic Diagram TCS Special Function Module: SVL Module
LVDT
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 18
2. TURBINE CONTROL SYSTEM
Sample: Servo Valve Actuation
From SVL Module (-50mA to +50mA)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 19
2. TURBINE CONTROL SYSTEM
TCS Hardware TCS Software Logic
TCS Special Function Module: TCL Module Executes the interlock logic with high response time for quick closing of governor valves.
TCL Module
OPC-1 TEST MODE
Parallel Operation (52G CLOSE)
TURBINE TRIP
SPEED ABNORMAL
OPC-2 TEST MODE
OPC-3 TEST MODE
OPC-1 Operated (from OPC module)
MSV CLOSE COMMAND (To SVL Module)
GV/ICV CLOSE COMMAND (To SVL Module)
OPC OPERATED
Local
S
OPC SV (Open) OPC-2 Operated
(from OPC module)
OPC-2 Operated (from OPC module)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 20
2. TURBINE CONTROL SYSTEM
Reference:
Detailed Schematic Diagram is available in Drawing No. 66400-7021 “Schematic Diagram For TCS And Turbine Communication Equipment Cabinet”.
Schematic Diagram TCS Special Function Module: TCL Module
TCL -A, B
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 21
2. TURBINE CONTROL SYSTEM Relation between TCS Special Function Modules
Software
Logic
(MPS)
・Speed detect
・EOST detect
Speed Pick Up×3
SVL Module×10×2
Servo Valve
LVDT
・Interlock Logic
・OPC 2 out of 3
TCL Module×2
Over Speed Protection
OPC Module×3
Generator MW
IP Inlet Steam Press.×3
Generator Current×3
Gen. Parallel Operation
EOST Operated
Forc
ed C
lose
C
omm
and
To TPS (Interlock)
TCS Panel
Turbine Tripped OPC
Solenoid
OPC Operated
PT
CT
MW
Speed
Control Demand
-50~+50 mA EOST Module×3
OPC Operate Command
Valve Demand Conversion
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 22
2. TURBINE CONTROL SYSTEM Sample: TCS Input & Output Interface
TCS
Servo Valve
Turbine Speed×3 (For Control & EOST)
Generator MW (for monitoring, Initial Load & Runback function)
Turbine Tripped ×3
Generator Parallel Operation ×3
IP Inlet Steam Press.×3 (for OPC)
Generator Current×3 (for OPC)
MSV (LH) MSV (RH) GV (LH1) GV (LH3) GV (RH2) GV (RH4) ICV (LH1) ICV (LH2) ICV (RH3) ICV (RH4)
LVDT (for each Valve)
PT
CT
MW
Linear Variable Differential Transformer
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 23
2. TURBINE CONTROL SYSTEM
(1) Speed control
(2) Valve Transfer (MSV/GV)
(3) Initial Load Control
(4) Load Limit/ Governor Control (GOV/LL Control)
(5) Valve test function
(7) Over Speed Protection Circuit (OPC)
(8) Electrical over speed trip (EOST)
(9) Other test (MOST/OPC/EOST test) Protective Function
(6) Vacuum Unloader (VU) Runback Function
(10) Stress Control / Monitoring
(0) Turbine Start-up Curve / Start-up Mode
TCS Control Functions
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 24
2. TURBINE CONTROL SYSTEM
Generator MW
Steam Admission
Rub Check
Heat Soak
Synchronization
Initial Load
Valve Transfer 3000rpm
2200rpm
500rpm
Speed Load
Time
100%
(0) Turbine Start-up Curve
Turbine Speed
2. TURBINE CONTROL SYSTEM
Control Stage Outlet Metal Temp
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 25
(0) Turbine Start-up Mode Start-up mode is determine based on Control Stage Outlet Metal Temp. START-UP
MODE Control Stage
Outlet Metal Temp COLD < 120℃ WARM 120℃ ~ 350℃ HOT 350℃ ~ above
2. TURBINE CONTROL SYSTEM
Speed Control
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 26
(1) Speed Control
Generator MW
Steam Admission
Rub Check
Heat Soak
Synchronization
Initial Load
Valve Transfer 3000rpm
2200rpm
500rpm
Speed Load
Time
100%
Turbine Speed
2. TURBINE CONTROL SYSTEM
Speed Control Demand
Speed Control (before valve transfer) is performed by MSV. All GVs are full opened.
Full Open Bias is added.
Bias is zero.
Full Open (No Control)
Control
Control
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 27
Governor Control Signal Flow
(1) Speed Control
GV Demand
ICV Demand
MSV Demand
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 28
EOST Module
Speed Detection
MED
SG
SG
SG
T
T
Speed Setter
3000
500
0
V> △ P
SG
SG
T
T Hold
Speed Rate
300rpm/min
0rpm/min
Fx SVL Module
MSV
Hard Ware Field
Hardware Field
①
②
③
Time
Act. Speed ②
Speed Ref. ①
③
Speed Target
2200
T
T SG
SG 150rpm/min 150
300
LVDT
3000rpm
2200rpm
500rpm
0rpm
(1) Speed Control
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 29
(1) Speed Control
Turbine Speed & Speed Rate operating window
2200
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 30
(1) Speed Control
<Critical Speed Area>
640 ~ 760 rpm
1090 ~ 1760 rpm
1890 ~ 2060 rpm
2390 ~ 2710 rpm
TCS prevents the Turbine running near
the critical speed
Turbine Speed & Speed Rate control plate
2200 rpm
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 31
(2) Valve Transfer
Valve Transfer Generator MW
Steam Admission
Rub Check
Heat Soak
Synchronization
Initial Load
3000rpm
2200rpm
500rpm
Speed Load
Time
100%
Turbine Speed Valve Transfer
2. TURBINE CONTROL SYSTEM
Posi
tion
Time
GV : Full Open
Valve Transfer
MSV Control
MSV : Full Open
GV Control
Speed Up Complete
After turbine speed up completed, turbine control mode is transferred from “MSV control mode” to “GV control mode”.
GV Open Bias becomes Zero
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 32
(2) Valve Transfer
MSV Open Bias maximum
2. TURBINE CONTROL SYSTEM
MSV Valve Transfer Bias
GV Valve Transfer Bias To Zero
To Maximum
Control
Control
Full Open (No Control)
Control
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 33
(2) Valve Transfer
Full Open (No Control)
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 34
(2) Valve Transfer
Valve Transfer operating window
2200
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 35
(2) Valve Transfer Valve Transfer
control plate
2200 rpm
2. TURBINE CONTROL SYSTEM
Before Synchronization
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 36
Load Generator MW
Steam Admission
Rub Check
Heat Soak
Synchronization
Initial Load
3000rpm
2200rpm
500rpm
Speed
Time
100%
Turbine Speed Valve Transfer
(3) Initial Load Control (Before Synchronization)
Control
2. TURBINE CONTROL SYSTEM
Before synchronization, speed Inc/Dec signals come from GCP (Generator Control Panel) (Auto / Manual Synchronization operation) and added to GOV Set Circuit.
GCP Speed Inc/Dec command
(3) Initial Load Control (Before Synchronization)
Control
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 37
Full Open (No Control)
2. TURBINE CONTROL SYSTEM
Initial Load Control
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 38
Generator MW
Steam Admission
Rub Check
Heat Soak
Synchronization
Initial Load
3000rpm
2200rpm
500rpm
Speed Load
Time
100%
Turbine Speed Valve Transfer
(3) Initial Load Control
Control
Control
Full Open (No Control)
2. TURBINE CONTROL SYSTEM (3) Initial Load Control
Initial load control is started when Circuit Breaker is closed. (5% of Rated MW as initial load).
Initial Load Control Demand
+
+
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 39
Load Control (by Turbine Master)
Generator MW
Steam Admission
Rub Check
Heat Soak
Synchronization
Initial Load
3000rpm
2200rpm
500rpm
Speed Load
Time
100%
Turbine Speed Valve Transfer
2. TURBINE CONTROL SYSTEM Load
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 40
(4) Load Limit/ Governor Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
During the load operation, GOV/LL mode can be selected.
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 41
Control
Control
Full Open (No Control)
(4) Load Limit/ Governor Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
GOV Mode (Frequency Compensation)
LL Mode (Load Limiter : Load Maintain)
GV Control Demand is determined by
“Load Demand” + “Frequency Compensation (DROOP)”.
GV Control Demand is determined by
“Load Demand” only.
Auto Follow Mode GOV mode + LL Auto Follow : LL demand is X% higher than GOV demand.
LL mode + GOV Auto Follow : GOV demand is X% higher than LL demand.
X% : Auto Follow Bias (Default : 5%)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 42
(4) Load Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
Frequency Compensation (DROOP)
Droop is applied for Frequency Regulation after Synchronization.
Droop is normally 4%.
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 43
(4) Load Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
B C
E D
A
a b
c
Power Supply Power Consumption
50Hz
d
e
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 44
(4) Load Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
B C
E D
A
a b
c
Power Supply Power Consumption
50Hz
d
e
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 45
(4) Load Control (GOV/LL Control)
f g h i
2. TURBINE CONTROL SYSTEM
B C
E D
A
a b
c
Power Supply Power Consumption
50Hz
d
e
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 46
(4) Load Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
B C
E D
A
a b
c
Power Supply Power Consumption
50Hz
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 47
(4) Load Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
Power Supply Power Consumption
50Hz
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 48
(4) Load Control (GOV/LL Control)
B C
E D
A
a b
c d
e
2. TURBINE CONTROL SYSTEM
Δrpm (ΔHz)
Droop Bias [%]
3120rpm (52Hz) 2880rpm (48Hz)
Droop 4% 3000 x 0.04 =120
100%
- 100%
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 49
Droop Bias
(4) Load Control (GOV/LL Control)
2. TURBINE CONTROL SYSTEM
GOV/LL Mode Switchover
△
3000rpm (50Hz)
MW
MWD
PI <L
+
△
FX
Turbine Speed
Droop
Turbine Master Controller +
SG 5% Auto Follow
LL mode signal
GOV mode signal 100%
Droop 4% Droop Bias%
rpm(Hz)
-100%
Coordination Control Circuit - DCS
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 50
(4) Load Control (GOV/LL Control)
GV
3000rpm (50Hz)
2880rpm (48Hz)
3120rpm (52Hz)
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 51
GOV/LL Mode Switchover (4) Load Control (GOV/LL Control)
Demand (%MW)
Time
LL
GOV
LL MODE GOV MODE GOV/LL Manual
- LL mode - GOV Auto Follow
- GOV mode - LL Auto Follow
Turbine Master Demand GOV/LL Reverse
GOV/LL Reverse
5% of Auto Follow (LL Auto Follow Rate: 100%/min)
2. TURBINE CONTROL SYSTEM
Switched
Parallel Mode
GV Lift
GV#1 ~ #4
Load
Sequential Mode
GV#1, 4 #2,3
GV Lift
Load
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 52
Valve Management (Sequential / Parallel Mode Switchover)
(4) Load Control
Parallel Mode
GV
Lift
GV#1 ~ #4
Load
Sequential Mode
GV#1, 4 #2,3
GV
Lift
Load
2. TURBINE CONTROL SYSTEM
1. Sequential Mode is applied as default mode for steam flow controllability. 2. In some case, at Sequential Mode, there is large difference in valve positions. Mode is change-over to Parallel mode to obtain more efficient operation.
Expected valve positions (as per design) at 30% Pressure Sliding condition.
Actual valve positions at 30% Pressure Sliding condition.
Valve positions after change-over
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 53
(4) Load Control Valve Management (Sequential / Parallel Mode Switchover)
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 54
(4) Load Control
Valve Management operating window
Load Control operating window
2200
Control
Control
Full Open (No Control)
2. TURBINE CONTROL SYSTEM
Bias is added for minus (-) direction during the valve test. Testing of Valves are divided into 2 groups as HP/IP group.
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 55
(5) Valve Test
2. TURBINE CONTROL SYSTEM
The valve test is perform to confirm the movement of valves (MSV and GV) during load operation. Before the test, TCS MW Control IN mode and APC Link-out should be selected, Gen. load is >50% and GV positions are >28%. Partial stroke test is applied to minimize main steam pressure loss and load fluctuation.
MSV(LH) MSV(RH)
0%
GV#1 GV#3 GV#2 GV#4
100%
GV Position
80%
GV Pos.-10%
TEST RESET
MSV (LH) TEST START TEST
COMPLETE
GV#1 TEST START
TEST RESET
TEST COMPLETE
Note: Individual Test for each HP valve
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 56
(5)-1 HP Valve Test
2. TURBINE CONTROL SYSTEM
The valve test is perform to confirm the movement of valves (RSV and ICV) during load operation. Before the test, TCS MW Control OUT mode and APC link-out should be selected, Gen. load is <100% and ICV positions are >90%. Full stroke test is applied since the influence on load fluctuation is relatively small compared to HP steam line.
0%
100%
Note: Individual Test for LH and RH © 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 57
(5)-2 IP Valve Test
ICV (LH)
RSV/ICV (LH) Test Start
RSV (LH) Test SV Open
RSV (LH)
RSV (LH)
ICV (LH)
RSV (LH) Test SV Close
RSV/ICV (LH) Test Complete
Valv
e P
ositi
on
ICV (RH)
RSV/ICV (RH) Test Start
RSV (RH) Test SV Open
RSV (RH)
RSV (RH)
ICV (RH)
RSV (RH) Test SV Close
RSV/ICV (RH) Test Complete
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 58
(5) Valve Test
Valve Test operating window
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 59
(5) Valve Test Valve Test control plates
2. TURBINE CONTROL SYSTEM
When the condenser vacuum is lower than the preset value, Vacuum Unloader is initiated and decreases the generator output load to maintain the vacuum. Runback rate is 10%/min (to be adjusted at commissioning stage).
Condenser Vacuum
Load (%) 25% 100%
Vacuum Unloader Operate Area
-0.846 bar
(639mmHg) (ANN)
-0.667 bar
(500mmHg) (TRIP)
Vacuum Unloader Operated
Operation Point
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 60
(6) Runback Function: Vacuum Unloader (VU)
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 61
(6) Runback Function: Vacuum Unloader (VU)
Vacuum Unloader operating window
Vacuum Unloader control plate
2200
2. TURBINE CONTROL SYSTEM
Protective Functions
(7) Electrical Over Speed Trip (EOST)
(8) Over Speed Protection Control (OPC)
(9) Test Functions (MOST/OPC/EOST)
(10) Stress Control / Monitoring
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 62
2. TURBINE CONTROL SYSTEM
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 63
(7) Protective Function: Electrical Over Speed Trip (EOST) Speed Pick-up Voltage is converted into rpm by EOST module. EOST contact is sent to TPS interlock circuit to make turbine trip.
Detecting Target of Turbine Rotor
(60 Teeth)
Electro-Magnetic Pick-up (Voltage Signal)
EOST MODULE -A
H/L
H/L
H/L To
TPS
TCS
EOST MODULE -B
EOST MODULE -C
Wave Count
rpm
Wave Count
Wave Count
> 3330rpm
Speed Control
EOST
Speed Control
Speed Control
> 3330rpm EOST
> 3330rpm EOST
rpm
rpm
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 64
2. TURBINE CONTROL SYSTEM
Schematic Diagram
Reference:
Detailed Schematic Diagram is available in Drawing No. 66400-7021 “Schematic Diagram For TCS And Turbine Communication Equipment Cabinet”.
(7) Protective Function: Electrical Over Speed Trip (EOST) EOST -A, B, C
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 65
2. TURBINE CONTROL SYSTEM
When turbine speed exceeds 107% of rated speed or load unbalance between required generator output and turbine input (IP turbine inlet steam pressure – generator current), OPC is initiated to prevent the over speed trip.
RPM
△MW(%) = IP Inlet Press (%) - Generator Current (%)
107 % (3210 rpm)
30% 60%
OPC Operating Zone
No Action
What is OPC Function ?
△MW(%)
(8) Protective Function: Over Speed Prot. Control (OPC)
© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 66
2. TURBINE CONTROL SYSTEM
OPC Operate Function
100
107
Speed(%)
0 30 60
OPC Operate
Load Unbalance(%) (IP Inlet Steam Press – Gen. Current)
OPC Module x 3
2/3
Forced Close Command To SVL Module (GV/ICV)
TCL Module x 2
Turbine Speed-1 Turbine Speed-2 Turbine Speed-3
IP Inlet Steam Press-1 IP Inlet Steam Press-2 IP Inlet Steam Press-3
Generator Current-1 Generator Current-2 Generator Current-3
(3210rpm)
S OPC SV
When OPC condition is detected, OPC module outputs “OPC Operated” signal to TCL module. TCL module makes OPC Solenoid Valves “Energized” (open) by 2 out of 3 logic to make GV/ICV closed.
(8) Protective Function: Over Speed Prot. Control (OPC)
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2. TURBINE CONTROL SYSTEM
OPC -A, B, C Schematic Diagram
Reference:
Detailed Schematic Diagram is available in Drawing No. 66400-7021 “Schematic Diagram For TCS And Turbine Communication Equipment Cabinet”.
(8) Protective Function: Over Speed Prot. Control (OPC)
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2. TURBINE CONTROL SYSTEM
MOST test
OPC Module test / OPC Actual Test
EOST Module test
Test functions for protective device and Special Function Modules are available in TCS as follows:
(9) Protective Function: Test Functions
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2. TURBINE CONTROL SYSTEM
To confirm actual Turbine trip by MOST (Mechanical Over Speed Trip) by manually increasing the Turbine Speed until above MOST setting of 110% (3300rpm).
Test is possible while turbine is at Rated Speed and at No Load condition.
1. Confirm Turbine is operating at 3000rpm and unsynchronized
2. Call “MOST Test“ control plate.
3. Select MOST Test mode “IN”.
4. Increase turbine speed gradually.
Purpose
Procedure
(9) Test Functions : MOST Test
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2. TURBINE CONTROL SYSTEM
(9) Test Functions : MOST Test
MOST Test control plate
MOST Test operating window
During MOST Test “IN” mode, the following changes applies automatically: • GOV SPEED SET upper limit from 106% (3180rpm) to 112% (3360rpm). • EOST setting from 111% (3330rpm) to 112% (3360rpm) . • OPC Function is out of service.
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2. TURBINE CONTROL SYSTEM
Purpose To confirm the function of each OPC Module without actual closing of GVs and ICVs.
During the test, a test bias signal is sent to the OPC module and confirm if the OPC operated signal will be generated.
Test is perform in one of the three modules at a time while turbine is at No Load condition.
(9) Test Functions : OPC Module Test
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2. TURBINE CONTROL SYSTEM
(9) Test Functions : OPC Module Test
OPC Test operating window
OPC Test control plate
1. Confirm Turbine is unsynchronized. 2. Call “OPC Test“ control plate (SPEED or LOAD). 3. Select “TEST” PB. 4. Select “FIX” or “VARIABLE” mode. If FIX mode is selected, a fixed value setting will be simulated. If Variable mode is selected, set point can be increased by control plate.
Procedure
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2. TURBINE CONTROL SYSTEM
To confirm the complete operation of OPC function.
Test is perform to all the three modules to actuate the OPC solenoid valves that will close the GVs and ICVs.
Test is possible while turbine is at No Load condition .
(9) Test Functions : OPC Actual Test
Purpose
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2. TURBINE CONTROL SYSTEM
(9) Test Functions : OPC Actual Test
OPC Actual Test operating window
OPC Actual Test control plate
1. Confirm Turbine is unsynchronized. 2. Call “OPC ACTUAL TEST“ control plate. 3. Select OPC Actual Test “IN” mode. 4. Select OPC Actual Test “ACTUAL COMMAND”.
Procedure
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2. TURBINE CONTROL SYSTEM
Purpose To confirm the function of each EOST Module without actual Turbine trip.
During the test, a bias signal is added to the Turbine speed and confirm if the EOST operated signal will be generated by EOST module with a setting of 111% (3330rpm).
Test is perform in one of the three modules at a time while turbine is at Rated Speed and No Load condition.
(9) Test Functions : EOST Module Test
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2. TURBINE CONTROL SYSTEM
(9) Test Functions : EOST Module Test
EOST Test operating screen
EOST Test control plate
1. Confirm Turbine is unsynchronized. 2. Call “EOST Test“ control plate. 3. Select “TEST” PB. 4. Select “FIX” or “VARIABLE” mode. If FIX mode is selected, a fixed value setting (11%) will be simulated. If Variable mode is selected, set point can be increased by control plate.
Procedure
2. TURBINE CONTROL SYSTEM
In order to reduce the stress on the turbine, the mismatch value between rotor average temperature and first stage steam temperature is calculated. Based on this mismatch, the Turbine speed up rate and load increase rate are controlled.
△T = (First Stage Steam Temp) – (Calculated Rotor Average Metal Temp)
TURBINE SPEED
STRESS CALCULATION
MAIN STEAM TEMP.
MAIN STEAM PRESS.
HP TURBINE INLET STEAM PRESS. CONTROL STAGE OUTLET METAL TEMP.
△T
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(10) Protective Function: Stress Control / Monitoring
2. TURBINE CONTROL SYSTEM
Turbine speed up rate is controlled except during critical speed.
SPEE
D
Time
△T > 60 degC
△T < 60 degC
Speed up operation
△T = (First Stage Steam Temp) – (Calculated Rotor Average Metal Temp)
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(10) Protective Function: Stress Control / Monitoring
SPEED RATE HOLD
2. TURBINE CONTROL SYSTEM
TURBINE SPEED
STRESS CALCULATION
MAIN STEAM TEMP
MAIN STEAM PRESS
HP TURBINE INLET STEAM PRESS
CONTROL STAGE OUTLET METAL TEMP
△T
H/L
X X
SG SG
STRESS LIFE TIME
CONSUMPTION CALCULATION
H/L
±60 ℃
52G CLOSE
NOT TURBINE TRIP
STRESS OPERATE SIGNAL (For Load Control Logic in Plant-DCS)
Stress Life Time Consumption Calculation Function Stress Operate Signal (for Load Rate Change in Coordination Control)
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(10) Protective Function: Stress Control / Monitoring
Stress Control “IN” mode
2. TURBINE CONTROL SYSTEM
Calculation Scheme
△T
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(10) Protective Function: Stress Control / Monitoring
2. TURBINE CONTROL SYSTEM
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(10) Protective Function: Stress Control / Monitoring
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