Al Qaim IRAQ -Steam Turbines Control · PDF fileAl Qaim Steam Turbines Control System is used...

Al Qaim IRAQ - Steam Turbines Control SystemAUTOMATION

INTEA d.d. Av. V. Holjevca 27, HR-10020 Zagreb, CROATIA tel: +385 1 3436 200 fax: +385 1 7898 860 e-mail: [email protected] http: //w ww.intea.hr

State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System

Plant OverviewAbout the PlantSCP chemical complex started production in 1985. Itconsists of integrated and interrelated plants to produce different kinds of phosphate fertilizers as a final product.

These plants are:• ore beneficiation plant U100,• sulfuric acid plant U200,• phosphoric acid plant U300,• utilities plant U620,• fertilizers plants U400,• ammonia plant U451,• fluorine salts plant U500,• materials handling plant.

ProductsMain SCP products are:• Fluorine salts• Ammonia• Sulfuric acid• Phosphoric acid concentration 54% (P2O5)• Center fertilizer phosphate (TSP)• Single phosphate fertilizer ammonia (MAP)• Composite fertilizer (NP, NPK).

Iraq Ministry of Industry and MineralsState Company for Phosphate

About SCPMain objectives of the company are:• exploration phosphate deposits• beneficiation of phosphate ores• production of phosphate fertilizers• production of compound fertilizers• production of by-products.



About the Project

The Project

"Rehabilitation of two steam turbines TG1 and TG2" project in Al Qaim Fertilizer Complex Power Station (Unit 620) was started in June 2010.

The purpose was to restore 2x14MW power generating capacity required for increasing of plant production and enabling overhauls of other plant sections.

Main contractor was INGRA M.E. d.o.o. - Zagreb-Croatia.

Site acceptance and successful hand-over were completed in April 2012.

Site works, including commissioning and start-up of the turbines and automation system, were completed by two INTEA engineers within twomonths.

Scope

Scope of the project was:• overhaul of the turbines and instrumentation, • replacement of turbines control system.

Main parts of the original, old control system:• steam turbine governors (BBC Turboturn 4),• protection (BBC relay cubicles) and• control panel.



New Steam Turbines Control System - Main Parts

Al Qaim Steam Turbines Control System is used for governing and protection of steam turbines. Main parts are:

• Two Steam Turbines Controller Cabinets (for TG1 and TG2)• Two Operator Stations • Engineering Station• Communication Networks• Printers• Uninterruptible Power Supply (UPS)

Steam Turbine Controller Cabinet contains 2 units ABB AdvantController 160

Enginering StationPC notebook computer with Microsoft Windows, 17" monitor and ABB 800xA Engineering Workplace system software.

Operator StationPC workstation (desktop computer) with AF100 communication module and ABB 800xA Operator Workplace system software.

PrintersTwo A4 laser printers for alarm and events printouts, report printouts, e.t.c. One A3 color ink jet printer - used for printouts of process graphics.

UPSStandalone UPS 230VAC for each ABB Operator Station,

Communication NetworksABB AdvantFieldbus 100 network is used for communication between process controllers and operator stations. Ethernet network is used for communication between operator stations and printers.



Control Netw ork AF100

Plant Netw ork (Ethernet)

Color InkJetPrinter (A3)

New Steam Turbine Control System - Configuration / Block Diagram

AC160Governor

Operator Workplace 1

LaserPrinter (A4)

UPS 230VAC

Operator Workplace 2

LaserPrinter (A4)

UPS 230VAC

EngineeringStation

Steam Turbine TG1

Advant Controller 160

AC160Governor

AC160Protection

AC160Protection

Steam Turbine TG2

I/O

~200

I/O

~200



Overview

Steam Turbine Controller Cabinet

Each Steam Turbine's control system is enclosed in its own cabinet (1600x2100x600 mm), containing:• two ABB Advant Controller 160 units (governor and protection),• power supply, • network equipment and • I/O modules. Each cubicle is equipped with all necessary terminals and interposing relays, wiring ducts, earth bars, lighting, anti-condensation heater and ventilation, 230V/50Hz power socket, door limit switch and is completely internally wired before the delivery. Ingress protection is IP54.

RedundancyThe whole system is redundant. In case of a problem or failure of any system device, another one with the same functionality automatically takes over and ensures continuation of normal system operation. For example, if one operator stations fails, operator can continue controlling both steam turbines using the other operator station.



Turbine Governor

Steam Turbine Control System - Main Parts

Each "Turbine Governor" AC160 controller has the following configuration:

• redundant processor (CPU),• redundant network equipment,• 32 DI (digital input) signals (24 VDC),• 16 DO (digital output) signals (relay contacts),• 32 AI (analog input) signals (4-20mA),• 8 AO (analog output) signals (0-20mA, 0-10V),• 3 DP (pulse input) signals for speed measurement.

Turbine Governor includes software functions of speed governor, overspeed protection, run-up and loading program devices, package of pressure controllers and limiters. Governor controller is basically controlling Control Valves (Live Steam and Cross-over).

The Governor operates on oneABB Advant Controller 160,with data bus system andredundant CPU. Overspeedprotection is a two-out-of-threesystem that is independent ofthe data bus system.



Turbine Protection

Steam Turbine Control System - Main Parts

Each "Turbine Protection" AC160 controller has the following configuration:

• redundant processor (CPU),• redundant network equipment,• 64 DI (digital input) signals (24 VDC),• 32 DO (digital output) signals (relay contacts),• 12 AI (analog input) signals (4-20mA).

Turbine Protection system operates on ABB Advant Controller 160 with data bus system and redundant CPU, separated from the Governor controller.Protection controller is controlling Main Stop Valve.

Redundant Control Network supports communication betwen Steam Turbine Controllers and Operator Stations.



Operator's Screen Example



Engineering Services

lNTEA - Delivery Scope

Project management

Design engineering• control system functional design specification• software design specification• site/construction related drawings and instructions• control system documentation: cabinet construction drawings,database and program listings, wiring diagrams, operating andmaintenance manuals, etc.• FAT procedures• onsite works descriptions and procedures• final as-built documentation

Application engineering• application engineering of steam turbine process controllers• application engineering of steam turbine operator stations• internal test in INTEA premises

HW manufacturing and assembling• assembling of steam turbine controller cabinets

FATDuring the Factory acceptance test all necessary tests werecarried out to verify that the complete system delivery is in accordance with contract specification and requirements. The tests were performed in accordance with INTEA standard test procedures and test protocols. FAT lasted one week.

Offsite trainingTraining course in Zagreb, with duration of 2 weeks, for 3 trainees. Each training session consisted of the following standard training courses:• Course CP001: STCS – Operation,• Course CP002: STCS Process Controller – Configuration and Maintenance,• Course CP003: STCS Operator Station – Configuration and Maintenance.

Site works• supervision of old equipment dismantling• erection and installation of new equipment• supervision of cabling and wiring to new steam turbine controller cabinets• supervision of power cabling from UPS cabinets to new controller cabinets• check of instruments connected to steam turbine control system• check of control devices controlled by steam steam turbine control system• check of related field wiring - loop checks• commissioning• start-up

Hardware Delivery• Two Steam Turbine Controller Cabinets (for TG1 and TG2)• Two Operator Stations • Engineering Station• Communication Networks• Printers• Uninterruptible Power Supply (UPS)

Al Qaim IRAQ -Steam Turbines Control · PDF fileAl Qaim Steam Turbines Control System is used...

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