Twitter Conference Hashtag: #EMRex

PresentersPresenters

Marius BizgaDCS Lead Engineer

Emil Viorel MihaiIT Manager

Oltenia Energy Complex

National Society of Lignite Oltenia – TARGU JIU

ROVINARI Energy Complex

TURCENI Energy Complex

CRAIOVA Energy Complex consists in Craiova II PP & Isalnita PP

Oltenia Energy Complex production capacity

Rovinari Power Plant: 4 x 330 MWIn the near future Rovinari PP is planning to implement between 2015-2017 a new 500MW unit supercritical boiler

Turceni Power Plant: 5 x 330 MW

Isalnita Power Plant: 2 x 315 MW

Craiova II Power Plant: 2 x 150 MW / 160 Gcal

Oltenia Energy Complex

Net Power 3012 MW

≈ 30% of SEN

A new challenge to Rovinari TPP - integrated Ovation Turbine controller with unit Ovation DCSA new challenge to Rovinari TPP - integrated Ovation Turbine controller with unit Ovation DCS

Rovinari TPP unit #4 is equipped with cRovinari TPP unit #4 is equipped with cooal fired 1035 t/h Benson Boiler and 330 MW steam turbine. There is al fired 1035 t/h Benson Boiler and 330 MW steam turbine. There is presented the technical solutions applied at turbine and feed-water turbo-pump digital control systems (Ovatiopresented the technical solutions applied at turbine and feed-water turbo-pump digital control systems (Ovatio nn DEH)DEH) - Rovinari PP unit no 4.- Rovinari PP unit no 4. A short presentation of the old control system; A short presentation of the old control system; The reasons to choosing the Ovation DEH solutions; The reasons to choosing the Ovation DEH solutions; Benefits using integrated Ovation DEH. Benefits using integrated Ovation DEH.

• Rovinari Power Plant is located 25 km S-W from Târgu Jiu and next to the town Rovinari.• very close to the coal pits

Due to its location, the power plant is directly fed, which is unique in Romania and offers the possibility to transform directly into energy the huge amount of coal from the pits which are included into the company ensuring a minimum transporting distance of the coal by conveyer belts.

Rovinari PPtechnical data

4 units x 330 MW

Boiler Type: once-through, Benson, tower Live steam pressure 196 bars Live steam temperature: 540 degC Live steam flow 1035 t/h Reheated steam temperature :540 degC

Turbine – F1C 330 1 x HP Case, 1 x IP case, 2 x LP case Speed 3000 rpm

Generator Rated active power 330 MW Speed 3000 rpm

Since 2003, at the power plant were carried out rehabilitation programs for the units

2004-2006 - first Ovation system was installed in Rovinari PP unit no 3

26-th of February 2006 – unit no 3 was coupled to the electricity network

Rovinari PP Installed Ovation Systems

Unit no 3 – including Polishing Plant

Unit no 6 – including Polishing Plant

Dense slurry evacuation

WFGD units no 3 & 6

Coal handling

Electric part of WFGD

Under implementation Unit no 4 and WFGD units no 4 & 5

The Turbine & BFTP Controllers units no 3 & 6 were purchased prior contracting DCS

The company that made the turbine retrofit delivered the whole package: the hydraulic and mechanical system retrofit and the control system.

Technical request for DCS included the interface to the Turbine & BFTP Controllers

Turbine and BFTP controllersunits 3 & 6

Interface DCS - controllers

• More than 160 points for turbine controller• More than 60 points for BFTP controller • Necessity of cables, galvanic isolators and interface relays• Increasing time of commissioning

During commissioning

During tuning & optimization

During normal operation

No redundant controllers

Difficulties

The turbine retrofit unit no. 4 was splited: Hydraulic and mechanical system retrofit Control system

Was necessary purchasing of controllers that use parts already included in the mechanical package 4 x HP Voith actuators , 1 x IP EHC Voith, speed sensors, etc. -

Main Turbine 3 x Voith actuators , speed sensors, etc. - BFTP

Safe & easy operation, easy installation

Primary and secondary load control

Reducing imbalances

Goals

Ovation DCS - Unit no 4 Emerson CSI Machinery Health Monitor – Protection and

Prediction DCS and turbine controllers are integrated in the same

system A unique database Redundant controllers No additional engineering and operator stations (already

in DCS) No necessary interfacing cables, galvanic isolators and

relays Ongoing Sure Service - Support & Maintenance contract

Why Ovation DEH?

Integrated solutionR

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Ovation Turbine Control Architecture

Redundant systems Processor I/O interface Network interface Power supplies

System same as rest of plant Controller hardware and I/O User Interfaces Network

Standard I/O cards for specialized turbine applications Speed cards Valve cards

Speed Detector Module

5 mSec update rate for overspeed protection with 16 bit resolution

Stand alone overspeed protection relay 16 mSec update rate for speed control with 32 bit

resolution One pickup per module Interfaces to existing pickups

Valve Positioner Module

Self calibrating EE memory for storing constants LVT or LVDT feedback Three redundant servo coil outputs On-board closed loop PI controller 10 mSec loop time Watchdog timer for shutdown Interfaces to existing hydraulic valves Variations for multiple channels Redundant Configuration

Servo Driver Module

PI control loop with 10 millisecond loop time Programmable PI gain and integral time constants Normal mode operation only 2 servo valve actuator coil drive outputs Supports redundant coil and dual LVDT capability 16 bit micro-controller Watchdog timer for servo valve actuator coil drive Watchdog timer for I/O bus Redundant feedback option for AC-LVT Redundant 24V power auctioneering Local calibration & tuning capability without trim pots Open-coil and shorted-coil diagnostic Runs seating and backseating logic Hot swap capability

Steam Turbine ControlMain functions

Steam Turbine ControlMain functions

Speed control before synchronization. Automatic turbine run-up. Synchronization. Load control. Live steam pressure control and its limitation. Primary frequency control and secondary frequency

control according to the Romanian Grid Code. Control valves position control. Control valves limits. Over speed protection control.

Steam Turbine Control Steam Turbine Control

Automatic Control (Auto Mode) Automatic Mode Loops Automatic Mode Limiters and Protective Functions Manual Control Manual Mode Limiters and Protective Functions Valve Position control Load reject Island mode

Automatic ControlAutomatic Control

In Automatic Control the operator can enter a speed, load or throttle pressure target along with a rate, which allow the controller to institute the desired ramp.

The controller includes logic to verify that the operator entered target and rate values are valid. In addition the system automatically verifies that the speed targets are not within any shaft resonance ranges. If the operator entered target speed fails these checks, the controller rejects these settings and holds the previous speed settings until valid settings are provided. High speed rate of change is applied automatically, when the turbine is crossing the critical speed zone.

There are three main control closed loops are available for control in the automatic mode: speed control, megawatt control, throttle pressure control. There are also related limiters to limit the unit output.

Automatic Mode LoopsAutomatic Mode Loops

Speed Feedback Loop

Open Loop Load Control

Megawatt Control Loop

Grid Load Frequency Control

The Throttle Pressure Feedback Loop

Automatic Mode LimitersAutomatic Mode Limiters

Valve Position Limiter Low Load Limiter High Load Limiter Throttle Pressure Limiter Reheat Pressure Limiter Low Condenser Vacuum Limiter Turbine thermal stress limits Turbine generator runbacks Overspeed Limiting Controller

Manual control In this mode the operator directly controls the valve demand

signal and the rate by increase and decrease pulses available on the display graphics, which give the system controls the turbine - generator unit speed, load or throttle pressure. The controller takes the operator valve demand setpoint and maintain the position relationship between the control valves. Valve characteristics are programmed into the Ovation DEH controller application software

Manual Mode Limiters Valve Position Limiter. Throttle Pressure Limiter. Reheat Pressure Limiter. Runbacks.

Overspeed Limiter

Valves position controlValves position control

The HP valve position control is performed by new Voith control magnets VRM, installed directly on the new actuators. They operate in a feedback control loops. The Ovation DEH controller will transfer position setpoints (hardwired, 4 ÷ 20mA) to the Voith position controllers.

The IP valve position control will be performed by new Voith electro-hydraulic converter. It will a single EH converter for four IP control valves. The Ovation DEH controller provide the position loop – Servo Driver Module.

Steam valves controls the steam flow according the existing procedures and characteristics. The HP valve characteristics are programmed in the Ovation DEH software.

Turbine valves testsTurbine valves tests

DEH Turbine Controller provides an operator interface to perform the turbine valves test.

Before unit start-up at low speed: Main stop valves tightness test Electrical overspeed test by means of simulation

Before synchronisation: Overspeed Protection Controller signal test Electrical overspeed trip test Mechanical overspeed trip test

On load: Mechanical overspeed trip test by means of oil simulation Main stop valves movement test IP control valves movement test

BFTP Turbine Control BFTP Turbine Control

Automatic Control (Auto Mode)

Automatic Speed Feedback Loop

Automatic Mode Limiters and Protective Functions

Manual Control

Manual Mode Limiters and Protective Functions

Valve Position control

Increased Availability Open Architecture Diagnostics to the I/O card level Alarm Diagnostics

Controller problem diagnostics Process alarming Problem with field sensors First out trip Power supplies failure diagnostics

Modular replacement of the existing control Multiple High Speed control loops Completely Integrated with total plant solution

Sequence of events Alarms Diagnostics

Common Training/Spares and Maintenance Programs

Benefits using integrated Ovation DEH

Cost reducing Cost reducing

Hardware cost reducing DB server/engineering station included in unit DCS Network equipment included in unit DCS Less I/O modules – more than 220 unnecessary hardware

points for both systems Unnecessary galvanic isolators & interface relays Unnecessary interface cables

Software cost reducing Ovation software included in unit DCS

Eliminate training cost Reduce the cost of commissioning Reducing service and maintenance cost

ConclusionConclusion

Integrated Ovation Turbine controller with unit Ovation DCS – The best solution!

Thank You!

Q&A!