capitulo 8 manual trend 60 wle
DESCRIPTION
CENTRALES TERMOELECTRICASTRANSCRIPT
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
Page 1
PACKAGE CONTROL SYSTEM
INTRODUCTION The control and protection systems permanently monitor the operating conditions of the plant. The control system adjusts plant parameters according to the conditions of operation. The protection system prevents a condition that can cause a risk to the plant. The control system is installed on a skid to minimize the number of interconnects. Off skid or inter-skid signals are through redundant ControlNet connections.
The Human Machine Interface (HMI) is a single point of access to view operation, maintenance and historical data. Access to the different functions is through passwords. The HMI communicates with the control system by Ethernet, for flexibility of location. The HMI enables the user to toggle the display of Rolls-Royce or Customer standard tagging, units of measurement and language. The primary operating HMI is located in the control room. Communication between the HMIs and the control systems uses the OPC (OLE for Process Control) protocol for data collation.
The Engine Control System (ECS) gives direct control of the Gas Turbine and fuel system. The Package Control System (PCS) has control over all Gas Turbine auxiliary systems. The PCS interfaces with the HMI, ECS, GCPP, and customer control systems. The Generator Control and Protection Panel (GCPP) supplies manual and auto synchronizing, voltage regulation, generator protection and metering and breaker control to the PCS.
A block diagram of the control system is shown in Fig 1.
UNIT CONTROL PANEL
The Unit Control Panel (UCP) contains the main control systems:
Package Control System (PCS)
Engine Control System (ECS)
Fire and Gas Controller (F&G)
Hardwired ESD (Emergency Shutdown)
Vibration and Overspeed Monitoring
The UCP is a two bay cabinet located in the customer control room. The panel is of folded steel construction with instruments and controls on the front. Access is through front doors with chromium plated locking handles.
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 2
PACKAGE CONTROL SYSTEM
The function of the package control system (PCS) is to monitor and control the gas turbine package system (i.e. mode selection, initiate start, sequence auxiliaries, load/unload, initiate synchronization). The PCS interfaces with the engine control system (ECS) for start/stop type control and direct control of all other equipment in the generator set. The ECS supplies closed loop and sequence control of the gas turbine directly. The PCS/ECS interface is a serial modbus link and hardwired I/O for backup.
The PCS supplies overall supervisory control of the gas turbine and generator and sequence control of the genset auxiliary plant.
Distributed I/O installed on the turbine generator package are much used. Communications between PCS and its distributed I/O is through redundant ControlNet communication.
The PCS has these functions:
Mode of operation selection logic (i.e. base etc.) Start sequence initiation, start auxiliary systems, verify auxiliary systems,
initiate purge sequences, and initiate ECS start
Scheduled shutdown initiation, cool down and coast down sequences for auxiliary systems
Interface with plant controls, data logging and trend monitoring system
Initiation of generator synchronization
Loading, unloading of generated power
The PCS controls these auxiliary systems:
Gas fuel system
Gas turbine lube oil
Hydraulic control oil system
Gas turbine enclosure cooling
Gas turbine bleed air cooling
Electric start system
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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The PCS interfaces with these auxiliary systems:
Engine control
Vibration
Fire and gas
Generator and auxiliary monitoring and protection
ENGINE CONTROL SYSTEM
The PCS interfaces with the engine control system (ECS) to supply start/stop type control and directly controls all other equipment in the generating set. The ECS supplies closed loop and sequence control of the gas turbine directly.
The ECS performs these functions:
Fuel / water system control and metering
Engine auto start control sequence
Low pressure (LP) compressor and intermediate pressure (IP) compressor inlet variable stator vane control
Compressor bleed valve control
IP/LP turbine tip clearance control
LP/IP shafts thrust piston control
Engine transient control
Flame out detection
Engine shutdown control
Engine protection shutdown control
Engine safe operating limit control/protection
Emission control
Shaft shear protection
LP/IP shaft overspeed protection
Loading and unloading rate control
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 4
Safety Instrumented System (SIS)
The safety instrumented system interfaces with the engine control system (ECS). It is a legal requirement to have a safety system as part of the overall control philosophy. Physically, the SIS resides alongside the ECS. The purpose of the SIS is to provide a duplex safety for key critical emergency shutdowns (ESDs). There may be over 100 ESDs as part of safe operation and control of the ECS system but some of these ESDs (25+) are highly dangerous and could cause an explosion or catastrophic incident. Therefore the shutdown signal for these special ESDs needs to be duplicated to ensure the shutdown signal is acknowledged at two sources (ECS/SIS) In the event of a critical ESD, two separate signals will command a shutdown at the safety relay interface. One signal comes from the ECS and the other identical signal will come from the SIS. Whichever signal reaches the safety relay first, will command the ESD.
The safety relay is the direct contact switch to the high speed shut-off valves.This relay can receive up to 12 individual commands to shut off the fuel (ESD). Some of the commands will come from the PCS, ECS, SIS, emergency hand stop switch and Fire & Gas System.
FIRE AND GAS CONTROLLER
The Fire and Gas (F&G) Controller, located in the UCP, monitors the fire and gas system through plant based instruments. The controller initiates discharge of the fire suppression equipment as required by plant conditions. The controller also initiates an emergency shutdown and interfaces with the PCS.
HARDWIRED ESD
The Hardwired ESD (Emergency Shutdown) system is located in the UCP and connected to the gas turbine (vibration and overspeed monitors) and to the generator (vibration monitors) The ESD system is outside of the processors for increased safety if PLC failure occurs. Each critical fail-safe shut down is wired to a master trip circuit and repeater contacts are wired to the processors input circuitry for annunciation and displays on the HMI. The HMI displays the alarm and trip points sequentially with time and date.
AC GENERATOR CONTROL AND PROTECTION PANEL (GCPP) The AC Generator Control and Protection Panel (GCPP) is a 2 bay cabinet located in the control room. The panel is of folded steel with instruments and controls on the front. Access is through front doors with chromium plated locking handles.
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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The GCPP contains the automatic voltage regulator (AVR), synchronizing, metering and protection for the AC generator. The equipment located in the panel is as follows:
AVR
Excitation controls
Auto synchronizer
Check synchronizer
Synchronizing control
Synchroscope
Metering equipment
These generator / transformer protection facilities are supplied:
Reverse power
Field
Negative phase sequence
Neutral displacement
Voltage dependant overcurrent
Undervoltage
Over frequency
Under frequency
AC generator differential
AC generator / transformer differential
AC generator hand lockout
Voltage balance
The PCS/GCPP is through a remote I/O and is located in an enclosure (the GCI - Generator Control Interface). The enclosure is installed adjacent to the GCPP and hardwired to the GCPP. The PCS interfaces to the GCI to receive the information.
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PACKAGE CONTROL SYSTEM 8 Page 6
The PSC/AC generator instrumentation interface is through dual redundant ControlNet.
The GCPP includes functions and equipment as follows:
Generator Instrumentation
1 Generator Voltmeter
1 Voltage Transducer
1 Voltmeter Selector Switch
1 Line Ammeter
1 Current Transducer
1 Ammeter Selector Switch
1 Frequency Indicator (tx) 1 Frequency Transducer
1 MW Indicator (tx) 1 MW Transducer
1 PF Indicator (tx) 1 PF Transducer
1 MVAr Indicator (tx) 1 MVAr Transducer Accuracy Class 1
1 12 Channel Temperature Monitor for Stator Winding, Bearings & Cooling Air
1 Exciter Field Ammeter (with Hi/Lo time delayed alarm contacts) (tx) 1 Ex. Field Current Transducer
1 Ex. Field Voltage Transducer
1 Exciter Field Voltmeter (tx) 1 Null Balance Meter
(tx = Transducer fed instrument)
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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Generator Indications
Generator Indications
1 Circuit Breaker Closed Lamp
1 Circuit Breaker Open Lamp
1 AVR in Auto Mode Lamp
1 AVR in Manual Mode Lamp
1 Voltage Control Selected Lamp
1 PF Control Selected Lamp
1 Excitation On Lamp
1 Push Button Lamp Test Circuit
Generator Controls
1 Circuit Breaker Control Switch Trip/N/Close
1 Governor Raise/N/Lower Switch
1 Excitation Off/On Switch
1 Auto/N/Manual Switch
1 AVR/N/Manual Switch
1 AVR Raise/N/Lower Switch
1 Manual Raise/N/Lower Switch
1 Local/Remote Selector
1 Voltage/PF Control Selector
1 Modular AVR Rack
Generator Protection
1 Three Phase Undervoltage Relay (27G) 1 Single Phase Reverse Power Relay (32) 1 Loss of Excitation Relay (40)
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 8
1 Negative Phase Sequence Relay (46) 1 3 Phase Voltage Controlled Overcurrent Relay (51V) 1 3 Phase Overvoltage Relay (59) 1 Voltage Balance Relay (60) 1 Rotor Ground Fault Relay (64E) 1 Stator Earth Fault Relay (64G) 1 Over / Underfrequency Relay (81) 2 Master Lockout / Trip Relay (86A+B) 1 High Speed Three Phase Differential Relay (87G) 4 Test Blocks
1 Test Block Plug (supplied loose) Synchronizing Equipment
1 Auto Synch Relay
1 Check Synch Relay
1 Auto/Manual/Off Synch Mode Selector
6 Synchronizing Selector Relays
1 Dead Bus Override Switch (Key Operated) 1 Synchroscope
1 Double Voltmeter
1 Double Frequency Indicator
2 Dead Bus Relays
1 Voltage Rise Relay
1 Lockout Timer Relay (Auto-synch) 1 Synch In Limits Lamp
Ancillary Equipment
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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30 Fuses / Holders
6 Auxiliary Relays
1 Interior Lamp and Door Switch
1 Anticondensation Heater, Switch and Thermostat
1 Set Customer Terminals
HMI SYSTEM
The human machine interface (HMI) is connected to the genset package through a dual redundant network connection. The HMI remotely controls the package. Each generator unit is controlled by moving the cursor on the display and changing the setpoint signals. The primary HMI is located in the control room with secondary installations at remote locations around the plant.
The HMI system supplies optimal information to the operator through the screen displays as follows, selected from a menu:
Multiple units overview
Unit Overview
Unit Permissives / Timers
Start Sequence
Generator Overview
Vibration
Lube Oil Systems
Valve Mimic
Event History
Alarm Shutdown Summary
Transmitter Failure
Historical Trending
Reporting (Standard) Calibration Screens
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 10
An EtherNet LAN is used for the onward link between the HMI system and the Station Control System (SCS - supplied by the Customer). Discrete signals are used to interface with SCS:
From SCS to Genset Control System:
Start
Stop
Base selection
Peak selection
Fast loading
Normal loading
Isochronous mode
Droop mode
Speed / load raise
Speed / load lower
Voltage raise
Voltage lower
Synch reset
GCPP Fault Acknowledge
From Genset Control System to SCS:
Ready to start
Load limit
Unit running
Failure to auto synch
Failure to start
Breaker closed
Start in progress
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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These signals are hardwired into the on base control system:
From SCS to Genset Control System
Plant emergency shutdown
Trip generator breaker
From Genset Control System to SCS
Genset trip.
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 12
FIG 1 BLOCK DIAGRAM OF CONTROL SYSTEM
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
Page 13
FIG 2 CONTROL SYSTEM CONCEPT
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 14
FIG 3 PCS/ECS BREAKDOWN
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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PCS vs ECS
PCS Engine Control System - Package Start/Stop Engine Control System
- Hydraulic Systems - Engine Start/Stop
- Lube Oil Systems - Fuel Metering
- Lube Oil Systems - LP/IP Thrust Pistons
- Enclosure Ventilation - Bleed Valves
- Generator - VIGVs
- Package Protection - LP/IP Tip Clearance
- Interface to SCS - Vibration Monitoring
- Package HMI - Engine Protection
Engine Protection System
- LP Shaft Overspeed
- IP Shaft Overspeed
Electrical VFD
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 16
FIG 4A TYPICAL HMI SCREEN
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
Page 17
FIG 4B TYPICAL HMI SCREEN
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 18
FIG 4C TYPICAL START HMI SCREEN
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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FIG 5 SYSTEM ARCHITECTURE
Dua
l Red
unda
nt C
ontro
lNet
Dua
l Red
unda
nt E
ther
net
Pack
age
Con
trol
Sys
tem
Mod
e S
elec
tion
Sta
rt In
itiat
ion
Aux
iliar
ies
Seq
uenc
ing
Sto
p In
itiat
ion
Spe
ed C
ontro
l
Engi
ne C
ontr
ol/S
IS S
yste
m
Prim
ary
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.C.
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asM
onito
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ibra
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itor
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esid
ent I
/O In
terfa
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rface
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ary
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acka
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istri
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ine
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ower
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ES
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ower
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d
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 20
FIG 6 PCS/ECS INTERFACES
Prim
ary
F.M
.V.
Driv
er
Sec
onda
ryF.
M.V
.D
river
Terti
ary
F.M
.V.
Driv
er
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R.S
.
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.C.
G.C
.P.
Gen
erat
or
Wat
er In
ject
ion
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erF.
M.V
.D
river
Fire
&G
as
Igni
ters
Mar
k 2A
And
Mar
k 3
Com
bust
or
Mar
k 2A
And
Mar
k 3
Com
bust
or
Mar
k 2A
Com
bust
or
Loca
l HM
I#1
Loca
l HM
I#2
U.H
.M.
100
M/b
it Et
hern
et H
ub #
2
100
M/b
it Et
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et H
ub #
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.S.
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.S.
Turb
ine
I/O
Spe
ed,
Vibr
atio
n, e
tc.
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inat
orTe
rmin
ator
DU
AL
RE
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ND
AN
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ON
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LNE
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CA
NB
US
DU
AL
RE
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ND
AN
TE
THE
RN
ET
RS
422
SE
RIA
LC
OM
MS
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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FIG 7 TYPICAL TRENT WLE CONTROLS PROCESS
FT125
FT125
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PACKAGE CONTROL SYSTEM 8 Page 22
FIG 8 CONTROL CABINET
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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FIG 9 PROGRAMMABLE LOGIC CONTROLLERS
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8 Page 24
FIG 10 SHUTDOWN RELAY AND SWITCHES
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TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL
PACKAGE CONTROL SYSTEM 8
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FIG 11 POWER PACKS
UNIT CONTROL PANELFIG 1 BLOCK DIAGRAM OF CONTROL SYSTEMFIG 2 CONTROL SYSTEM CONCEPTFIG 3 PCS/ECS BREAKDOWNFIG 4A TYPICAL HMI SCREENFIG 4B TYPICAL HMI SCREENFIG 4C TYPICAL START HMI SCREENFIG 5 SYSTEM ARCHITECTUREFIG 6 PCS/ECS INTERFACESFIG 7 TYPICAL TRENT WLE CONTROLS PROCESSFIG 8 CONTROL CABINETFIG 9 PROGRAMMABLE LOGIC CONTROLLERSFIG 10 SHUTDOWN RELAY AND SWITCHESFIG 11 POWER PACKS