TS3000

INVENSYS PROCESS SYSTEMS (S) PTE LTD

DOCUMENT TITLE : Basic Of Design Document

DOCUMENT NO : MD-502-7000-IN-BOD-1025-1013 REQUISITION NO : KAR 760 PURCHASE ORDER NO : 4500039280 ITEM NO : All Items ITEM DESCRIPTION : ITCC

□ APPROVED □ WITH COMMENT

□ REVIEWED □ RESUBMIT

This approval or review does not relieve the vendor / subcontractor of his responsibilities to meet all requirements of the purchase order

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DATE

SAMSUNG ENGINEERING CO., LTD

D02 04Dec2009 Final(For Record) HDY NDD JIY

D01 23Feb2009 As-Built PDK MN JIY

C01 22Dec2008 Issue for Construction PDK MN JIY

A01 18Sep2008 Issue for Approval SHE MN JIY

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

SAUDI ARABIAN MINING COMPANY(MA'ADEN)

MA'ADEN AMMONIA PROJECT

Worley Parsons

SAMSUNG ENGINEERING CO., LTD. SEOUL KOREA

SECL PROJECT NO. : SC2158

Uhde GmbH

leeling.woo

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(File Name: SG60016-TC1-TMC-BODD-30001-RD02.doc)

Document SG60016-TC1-TMC-BODD-30001 Customer MD-502-7000-IN-BOD-1025-1013 Contract No. 4500039280

Project No. SG60016

INVENSYS PROCESS SYSTEMS (S) PTE LTD of 43 PROJECT NAME : MA’ADEN AMMONIA PROJECT CUSTOMER NAME : SAMSUNG ENGINEERING CO. LTD ENDUSER NAME : SAUDI ARABIAN MINING COMPANY (MA’ADEN) LOCATION : KINGDOM OF SAUDI ARABIA

Basis of Design Document

7120-J01-TS01

Steam Turbine Generator

D02 04Dec09 HDY NDD JIY Final(For Record) D01 23Feb09 PDK MN JIY As-Built C01 22Dec08 PDK MN JIY Issue for Construction A01 18Sep08 SHE MN JIY Issue for approval Rev Date Prep’d Chk’d Apr’d

Project Name: MA'ADEN AMMONIA PROJECT Doc. No. : SG60016-TC1-TMC-BODD-30001 Rev. : D02 Project Location : Ras Az Zawr City ,KSA Project No. : SG60016 Document Description : Basis of Design Document Contract No. : 4500039280 Area/Unit/System Description – 7120-J01-TS01 Page : 3 of 43 Customer Doc:- MD-502-7000-IN-BOD-1025-1013



TABLE OF CONTENTS

1 GENERAL...................................................................................................... 5 2 APPLICATION OVERVIEW ............................................................................. 7 3 INTERFACE DESCRIPTION ............................................................................. 9 4 SEQUENCE DESCRIPTION (7120-J01-TS01) ................................................... 10

4.1 INTRODUCTION.............................................................................................................. 10 4.2 MODE ASSIGNMENTS ................................................................................................... 10 4.3 MODE 0 – TURBINE SHUTDOWN............................................................................... 14 4.4 MODE 1 – READY-TO-START....................................................................................... 15 4.5 MODE 2 – 2ND IDLE SPEED (1000 RPM) .................................................................... 16 4.6 MODE 3 – ACCELERATION........................................................................................... 18 4.7 MODE 4 – RATED SPEED (5194 RPM)........................................................................ 19 4.8 MODE 5 – ONLINE OPERATION.................................................................................. 20 4.9 MODE 6 – ISLAND OPERATION .................................................................................. 22 4.10 MODE 7 – OVER SPEED TRIP TEST ............................................................................. 23

5 CONTROL DESCRIPTION (7120-J01-TS01)..................................................... 24 5.1 GENERAL........................................................................................................................... 24 5.2 NAMING CONVENTION................................................................................................ 25 5.3 CONSTANT INITALIZATION......................................................................................... 27 5.4 ANALOG INPUT SCALING............................................................................................. 27 5.5 TRIPS & ALARMS............................................................................................................. 28

5.5.1 TRIPS ............................................................................................... 28 5.5.2 ALARMS ........................................................................................... 28

6 7120-J01/7120-J01-TS01 CONTROL MODULE DESCRIPTION........................... 30 6.1 CONTROL MODULE ASSIGNMENT............................................................................. 30 6.2 7120-J01-TS01 STEAM TURBINE CONTROL MODULES ......................................... 31

6.2.1 SP1 – SPEED INPUT MEDIAN SELECT................................................. 31 6.2.2 SP2 – TARGET SPEED SETPOINT........................................................ 32 6.2.3 SP3 – SPEED SETPOINT RAMP........................................................... 33 6.2.4 SP4 – SPEED DROOP......................................................................... 34 6.2.5 SP5 – SPEED PID............................................................................... 35 6.2.6 MW1 – SPEED SETPOINT RAMP ........................................................ 36 6.2.7 MW2 – MW PID................................................................................ 37

6.3 TRANSMITTER FAIL-OVER STRATEGY ................................................................... 38 7 DUAL COIL ACTUATOR CONFIGURATION ................................................... 39




APPENDIX A – CONSTANT LIST ......................................................................... 40 APPENDIX B – INTERFACE LIST.......................................................................... 41 APPENDIX C – ANALOG INPUT RANGES ............................................................ 42 APPENDIX D – APPLICATION DETAIL ................................................................. 43




1 GENERAL The Basis of Design Document defines the Triconex Steam Turbine/Generator Control System

for the MA'ADEN AMMONIA Plant Project, and provide general control guidelines for Startup,

Speed Control, Shutdown, and Anti-Surge Control and other control functions for 7120-J01 –

Generator provided to Samsung Engineering Co., Ltd, for Ma’aden by Invensys Process System

(s) Pte Ltd, Triconex. (Hereafter referred to as IPS). Once approved, this document forms the

basis for designing this system.

Relevant identification data:

Customer: Samsung Engineering Co., Ltd

End User: Ma'aden Company.

Project: Ma'aden Ammonia Project

System Type: TS3000 (TRICON)

Location: Ras Az Zawr City ,KSA

For the development of the detailed design, MHI will provide IPS with the following:

• I/O Assignment

• Field Cable Schedule

• P&ID

• Control Narrative

• Turbine Startup Curve

• Expected Performance Curve




The Triconex TS3000 (TRICON) Control System is based on the Triconex Tricon Controller - a

state-of-the-art fault-tolerant controller based on the Triple Modular Redundant (TMR)

architecture. TMR employs three identical isolated system legs of which each leg

independently executes the control program in parallel with the other two legs. This tolerates

and ensures that a single point of failure will not affect the other “healthy” legs.

The TMR system uses two-out-of-three voting architecture to ensure high integrity and

reliability of the I/O signals. On-line replacement and hot sparing of the I/O modules are

possible. This will eliminate any undue interrupt to the process or operation should a fault

occur in the module.

The entire plant is designed to be fail-to-safe mode. Therefore, the field inputs or outputs are

normally in the “Close” or “Energize” state respectively when in normal condition. A logical ‘1’

input signal to the TMR system is treated as a normal state and a ‘0’ logic signal is treated as

trip or failure state. Upon total power failure, the output signals should go to ‘0’ state.




2 APPLICATION OVERVIEW

This application provides Governing and Load Control for the Steam Turbine-Driven

Generator Set (7120-J01-TS01).

TS3000 control system will provide the following main functions:

• Auto Startup Sequence

• Off-Line Speed Control

• On-Line Speed Droop Control

• Load (Megawatt) Control

TS3000 will also perform the following:

• Alarming and Tripping




Figure 2-1 Application Overview (turbine control)




3 INTERFACE DESCRIPTION

The Triconex TS3000 (TRICON) system provides control for the start-up of the Turbine

through, HMI (Local) and DCS (Remote).

The Remote/ Local Selection can be selected from HMI (f7120REMLOC). Remote/Local status

indication will be in HMI and DCS. In Local mode, Operator can issue command from HMI,

and when in Remote from DCS.

Please refer to Appendix B for Interface List.




4 SEQUENCE DESCRIPTION (7120-J01-TS01) 4.1 INTRODUCTION This section defines the control implementation in the TS3000 (TRICON) Generator - Steam

Turbine (7120-J01-TS01), and discusses the following:

• Sequence Modes

• Description of the sequential operation 7120-J01-TS01 Steam Turbine

• Control Description

4.2 MODE ASSIGNMENTS The TS3000 (TRICON) Startup/ Shutdown Sequence is organized into a series of Modes or

states defining the progressive stages of the turbine startup and any special considerations

involved with the execution of a given Mode. Each defined Mode is assigned a sequential

number used within the TS3000 (TRICON) logic. The sequence logic decides which Mode may

be entered from the current Mode. This ensures an orderly progression through the Modes

and appropriate actions in the event of an operational change.

The sequence mode variable “i7120MODE” defines the various starting, operating, and test

Modes that control the program. The sequence of operation for the 7120-J01-TS01 Steam

Turbine Control System for Generator will be determined by these modes.

Mode Description

Mode 0 Turbine Tripped/Shutdown

Mode 1 Ready to Start

Mode 2 2ND Idle Speed (1000 RPM)

Mode 3 Acceleration

Mode 4 Rated Speed (5194 RPM)




Mode 5 Online Operation

Mode 6 Island Operation

Mode 7 Overspeed Test

Refer to Figure 4-2-1 7120-J01-TS01 Steam Turbine Start-up Sequence

The Startup Sequence is organized into a series of modes or states defining the progressive

stages of the turbine startup and any special considerations involved with the execution of a

given stage.

Each defined mode is assigned a sequential number used within the TS3000 logic. The

sequence logic in the TS3000 controls which mode may be entered from any given current

mode ensures an orderly progression through the modes and appropriate actions in the

event of mechanical malfunctions.




Mode 0Shutdown

Mode 1Ready to Start

Mode 22nd Idle Speed

( 1000RPM)

Mode 3Acceleration( 5194RPM)

Mode 5Online

Operation

All Trip Cleared & Start Permissive Clear

Start Command

Rated Speed Command

Any Trip

Any Trip

Any Trip

Mode 6Island

Operation

Over Speed Test On

Any Trip

Over Speed Test Off

Idle Speed Command

Any Trip

Mode 7Over Speed

Trip Test

Generator Breaker Opened

Generator Breaker Opened

Utility Tie Breaker Closed

Utility Tie Breaker Opened

Any Trip

Mode 4Rated Speed( 5194RPM)

Speed = 5194 RPM

Utility Tie Breaker Closed

Figure 4-2-1 7120-J01-TS01 Steam Turbine Start-up Sequence




Figure 4-2-2 7120-J01-TS01 Steam Turbine Start-up Curve




4.3 MODE 0 – TURBINE SHUTDOWN

Entered

From

Condition Remarks

Any Mode Whenever the turbine is tripped.

If the Trip has not been reset, the TS3000 (TRICON) will remain in Mode 0, Shutdown. It will be prevented from starting until all trips conditions have been cleared and the system has entered Mode 1, Ready-to-Start. Refer to Table 5-5-1 for list of Trip signals

Initial When TS3000 (TRICON)

is powered up.

In this Mode:

Action

The Speed Controller output is clamped to 0%.

The minimum and maximum limits on the Governor valve are set to 0 %.

The Actual Speed Set point and Target Setpoint are set to 0 RPM.

The minimum and maximum limits on the Actual Speed Setpoint are set to 0 RPM.

Common Trip Signal will be sent to DCS/HMI/ESD.




4.4 MODE 1 – READY-TO-START

Entered

From

Condition Remarks

Mode 0 Shutdown

All Trips clear and reset and Governor Start Permissive received from DCS

In this Mode:

Action

Ready to Start Signal will be sent to DCS/ HMI.

The Speed Controller output is clamped to 0%.

The minimum and maximum limits on the Governor valve are set to 0 %.

The minimum and maximum limits on the Actual Speed setpoint are set to 0.




4.5 MODE 2 – 2ND IDLE SPEED (1000 RPM)

Entered

From

Condition Remarks

Mode 1 Ready to Start

A Start Command from HMI (Local) / DCS (Remote) is issued.

The turbine is started manually. Trip and throttle valve will be open gradually by operator. Operator wills warm-up the turbine at approximately, the 1ST Idle Speed (500 RPM) for around 34 minutes as per the startup procedure (it depends on the start-up conditions) After Warm-up at 1ST Idle Speed of 500 RPM is completed, operator may proceed to fully open the T&T Valve. TS3000 (TRICON) will control speed at 2ND Idle Speed of 1000 RPM via V1. The Turbine will be allowed to run at 2ND Idle speed for around 30 minutes as per the startup procedure. NOTE: If the turbine speed increases above 1000 RPM, the Governor Valve, V1 will throttle and take control of the speed. Warm-up Timers are for indication only

Mode 3 Acceleration

“Idle Speed” Command from HMI/DCS is issued and turbine speed is between 2ND Idle speed and Rated speed.

The turbine speed will decreased to 2ND Idle speed.




In this Mode:

Action

The Peak Speed Recorder is reset and begins recording maximum speed.

Trip Speed recorder is reset.

The Actual Speed Setpoint is clamped between 0 and Rated Speed. The Target Speed setpoint is set to 2ND Idle Speed (1000 RPM). The Actual Speed setpoint

is ramped towards the target at normal ramp rate (300 RPM/min).

Countdown timers are reset.

1ST Idle Speed Countdown timer is started once 450 RPM is reached. The count down

stops any time the speed drops below 400 RPM or rises above or equal 550 RPM.

2ND Idle Speed countdown timer is started once 950 RPM is reached. The count down

stops any time the speed drops below 900 RPM or rises above or equal 1050 RPM.

Both timers are for indication only.

Start-up speed tuning parameters for the speed controller are used.

The governor valve maximum opening limit default to 80%. Operator can raise/lower this

limit from HMI




4.6 MODE 3 – ACCELERATION

Entered

From

Condition Remarks

Mode 2 Idle Speed

A “Rated Speed” Command from HMI/DCS is issued and turbine speed is within 50 RPM of 2ND Idle Speed

Turbine will be brought to Rated speed.

In this Mode:

Action

The Target Speed Setpoint is set to Rated speed (5194 RPM). The Actual Speed Setpoint

is ramped to the target at normal ramp rate (300 RPM/MIN). During Critical Speed Band,

the Actual Speed Setpoint is ramped towards the target at fast ramp rate (1000

RPM/MIN).

The operator can press the speed “Halt” pushbutton from DCS/ HMI provided the Actual

Speed Setpoint and Actual Speed are not in the Critical Speed Band. This will cause the

turbine sequence to stop. The Target Speed Setpoint will be set to the current Actual

Speed Setpoint. The operator can now raise or lower the Target Speed Setpoint from

DCS/ HMI. The turbine sequence continues when operator press speed “Continue”

pushbutton from DCS/HMI.

An indication will be sent to DCS/ HMI when actual speed is in the Critical Band.




4.7 MODE 4 – RATED SPEED (5194 RPM)

Entered

From

Condition Remarks

Mode 3 Acceleration

Actual speed reaches 50 RPM below the Rated Speed (5194 RPM).

Mode 5 Parallel OR Mode 6 Island

Generator Breaker has been Opened

Mode 7 Over Speed Trip Test

An “Over Speed Trip Test” Off command from HMI is issued.

In this Mode:

Action

The Actual Speed Setpoint is clamped 5094 RPM and 5294 RPM.

Target speed setpoint can be raised /lowered from DCS/HMI

The Actual Speed Setpoint is ramped to the target at ramp rate (300 RPM/MIN)

Over Speed Trip Test can be enabled/disabled from HMI.




4.8 MODE 5 – ONLINE OPERATION

Entered

From

Condition Remarks

Mode 4 Rated Speed

Utility Breaker and Generator Breaker have been closed

Mode 6 Island

Utility Breaker has been closed

In this Mode:

Action

Upon first entering this mode,

1- The speed controller setpoint is memorized, for subsequent load rejection recall.

2- Governor valve is stepped by a fixed amount (3~10%) to prevent reverse power on

breaker closure and positive generation.

The Speed Droop control and MW control are enabled.

Target Speed Setpoint can be raised / lowered from DCS/HMI.

The Actual Speed Setpoint is clamped between Rated Speed (5194 RPM) and Maximum

Speed (5454 RPM based on 5% droop).

Speed Droop control is set to control the system initially.

MW Control can be activated by

1- Press “SPEED REF RAISE” on DCS/HMI until actual MW is higher than Remote MW or

set Remote MW value lower than the actual MW.

2- Continue pressing “SPEED REF RAISE” pushbutton on DCS/HMI until speed reference

reaches the maximum speed

3- When MW controller output is less than speed droop controller output, MW control

is activated.




Action

The governor valve will open according to the lowest output between the speed droop

controller and the MW controller.

While in MW control mode, the control system accepts a 4-20mA control signal from the

DCS. The MW target is set to this remote setpoint. Actual MW setpoint ramps to the

target value at the rate 1.3 MW/Min. MW setpoint is limited to the max MW.

If the MW setpoint is lost when running in MW control mode, MW setpoint will be

ramped to the maximum MW value, the control will switch to speed droop control.

If the MW Transmitter fails while running in MW control mode, MW setpoint will be

ramped to the maximum MW value, MW signal will keep the last good value, the control

will switch to speed droop control.




4.9 MODE 6 – ISLAND OPERATION

Entered

From

Condition Remarks

Mode 5 Parallel

Utility Breaker has been opened

In this Mode:

Action

Upon first entering this mode, the Target Speed Setpoint and Actual Speed Setpoint is set

the Rated Speed for the duration of 1 scan time. The speed PID output will be set to the

governor valve output just before entering Island Mode for the duration of 1 scan time

(to quickly transfer the control from MW control to speed droop control).

The MW setpoint will be ramped to maximum value.

The MW control is disabled and the governor valve will be under speed droop control

Target speed Setpoint can be raised / lowered from DCS/HMI




4.10 MODE 7 – OVER SPEED TRIP TEST

Entered

From

Condition Remarks

Mode 4

Rated Speed

“Over Speed Trip Test” from HMI is switched to EOST or MOST

In this Mode:

Action

Over Speed Test indication will be sent to DCS/ HMI. The Actual Speed Setpoint high limit is changed to 5750 RPM

IF EOST is selected: • Turbine trips at EOST trip setpoint of 5661 RPM, when the speed is increased

from HMI/ DCS. • The turbine will be tripped by the Protech at 5674 RPM if the EOST fails to trip

the turbine. IF MOST is selected:

• Governor Overspeed trip setpoint automatically changes to 5713 RPM. • Turbine trips at Protech trip setpoint of 5674 RPM, when the speed is increased

from HMI/ DCS. • The turbine will be tripped by EOST at 5713 RPM if the Protech fails to trip the

turbine.




5 CONTROL DESCRIPTION (7120-J01-TS01) 5.1 General

Depending on operating conditions and load demand the valve position reference can be

controlled (limited) by any of the following:

• Speed control (Offline)

• Speed Droop control (Online/Island)

• Megawatt control (Online)

This section describes the control system by function.

Refer to the Control Block Diagram in Figure 6-1-1




5.2 NAMING CONVENTION

The following describes the TS3000 Soft Tag naming convention used for identifying each

different type of I/O and location.

All I/O are in a general format of “xAAAA”, where:

“x” is a small cap prefix, which refers to the I/O’s signal type

“AAAAA” refer to the I/O’s Tagname

Naming convention for I/O signal type “x”

Hardwired Signals;

Prefix Signal

w Analog Inputs

y Unscaled Analog Outputs

t Thermocouple Inputs

d Digital Inputs

c Digital Outputs

p Pulse Inputs

Memory Signals:

Prefix Signal

f Digital Memory

m Digital Memory Alarm

g Digital Memory Enterable




Prefix Signal

i Analog Memory Integer

r Analog Memory Real

e Analog Memory Enterable

k Constant Memory

All Alarm/Trips are in a general format of “mAAAA_FO”, where:

“m” is a small cap prefix, which refers to the I/O’s signal type

“AAAA” refer to the I/O’s Tagname

“FO” is a capital suffix, which refer to First out flag.

Example:

mTBA - Common shutdown to DCS

mTBA_FO - First out Alarm

kNORRR - Actual Speed Setpoint Normal Ramp Rate

kFASTRR – Actual Speed Setpoint Fast Ramp Rate




5.3 CONSTANT INITALIZATION

Constant initialization passes the constant values to the tags which are defined in the logic.

These constant values are passed during the first scan of TS3000 (TRICON) operation. Please

refer to Appendix A for tags and their values in the Constant List.

5.4 ANALOG INPUT SCALING All analog inputs are scaled and any square rooting or filtering is performed (as required). It

will also perform signal selection (HI, LOW, Mid-selects or any averaging). Alarms that are

based on input values or failures are also generated. If fallback or safe values are associated

with inputs these values will reside in the appropriate module related to that control function.

Analog inputs that have exceeded the allowable range of 3.2 mA and 21.6 mA will have their

respective failure flags set false. If an analog input fails, it will remain failed unless it returns to

the acceptable range and remains in this range for a period of five minutes. Please refer to

Appendix C for Analog Input Ranges.




5.5 TRIPS & ALARMS 5.5.1 TRIPS

The following conditions trip the turbine:

Description From Trip Setpoints

Trip Tagnames

When TS3000 (TRICON) is powered down

- -

External trip from ESD ESD False 7120-X-12.41T

Fail Safe Trip TS3000

(TRICON) False 7120FSTRP

EOST trip TS3000

(TRICON) 5661 RPM 7120OSTRP

Governor valve 2 coil fail TS3000

(TRICON) False 7120V1TRP

All speed pickups fail trip TS3000

(TRICON) False 7120SPDFAILTRP

Table 5-5-1-1: Trip Table

A first out block will record the trip that caused the TS3000 (TRICON) Shutdown. An internal

trip flag will trigger the first out capture. First out flags will be reset when sequencing enters

Mode 1. Data will be generated in the TS3000 (TRICON) and will be captured/ logged in the

HMI/ DCS/ SOE.

5.5.2 ALARMS An alarm is a visual indication of an abnormal event or process condition which requires

attention and/or corrective action from the operator. Alarms generated within the TS3000

(TRICON) will be recorded and captured/ logged in the HMI/ DCS/ SOE. Please refer to

Appendix B for Interface List.




The valve position feedback will be continuously monitored and a deviation alarm will be

generated if the difference between the valve output and the valve position feed back signal is

higher than or equal 20% for 2 seconds.




6 7120-J01/7120-J01-TS01 CONTROL MODULE DESCRIPTION

6.1 CONTROL MODULE ASSIGNMENT

The control function is organized into Modules, with each Module performing specific tasks.

Figure 6-1-1 Control Modules The following is a list of control modules used in this application. They are presented here in

execution order.

Module Function

SP1 Speed Input Median Select

SP2 Target Speed Setpoint Generator

SP3 Speed Setpoint Ramp.

SP4 Speed Droop

SP5 Speed PID

MW1 MW Setpoint Ramp

MW2 MW PID

Table 6-1-1: Control Modules

SP5Speed

PIDSP1Speed Input

Median Select

SP2Target Speed

Setpoint

SP3Speed

SetpointRamp

Speed B

Speed A

Speed C

Operating Mode

Speed Raise/ Lower

Governor ValveSV-2410

Speed Setpoint

Target Speed Actual Speed Setpoint

Actual Speed

Speed Controller Output

Low

SelectorSP4

Droop

Drooped Speed Setpoint

Drooped Speed Measurement

MW1Megawatt Setpoint

Ramp

MW SetpointFrom DCS MW2

MegawattPID

Actual MW Setpoint

MW Measurement




6.2 7120-J01-TS01 STEAM TURBINE CONTROL MODULES 6.2.1 SP1 – SPEED INPUT MEDIAN SELECT

This module calculates a combined speed measurement based on the values of the three

speed pickup inputs. It will continually output a selected speed value based upon the number

of good speed pickups. The function returns an output value of zero when all enabled speed

pickups fail or all are disabled. Low speed failure testing can be enabled when certain pre-

determined condition are met.

Logic

• Pickup failure logic is enabled when the turbine reaches Mode 2 and the speed is

above 250 RPM.

• Once speed pickup failure detection is enabled, a pickup will fail if it drops below

200 RPM.

• The median value of the three speed pickup is used for Speed Control.

• If one pickup fails, the higher of the two remaining good speed pickup will be used.

• If two pickups fail, the remaining speed pickup will be used.

• The turbine will be tripped when three pickups fail.

• The turbine will be tripped when actual speed indicates a speed above the over

speed trip setpoint.

• Peak Speed and Trip Speed will be recorded. These variables will be reset upon

entering Mode 2 from Mode 1.




6.2.2 SP2 – TARGET SPEED SETPOINT Based on the current turbine Mode and various operator inputs, this module produces a target

speed setpoint. Since its value changes instantaneously, a ramp function (Module SP3) is used

to smooth out the output prior to use by the PID.

Logic

• Based on the current turbine Mode and various Operator inputs, this module

determines the target speed setpoint.

• Reference the Sequencing Logic Description for additional detail.

• Target Speed Setpoint tracking in Mode 4 only.




6.2.3 SP3 – SPEED SETPOINT RAMP

Ramp blocks are used to move any of the various actual setpoints to their associated target

setpoints at a steady, smooth rate. It is designed for speed setpoint ramping with critical

speed band evasion, and speed target setpoint clamping within operating limits. This prevents

step changes in the setpoints that could cause instability in the control loop.

Logic

• In Modes 0 or 1, the Target Speed Setpoint and the Actual Speed Setpoint is set to 0

RPM.

• In all other mode, the Actual Speed Setpoint is ramped towards the Target Speed at

the normal ramp rate (300 RPM/MIN).

• In the critical speed band, the Actual Speed Setpoint is ramped towards the Target

Speed at the fast ramp rate (1000 RPM/MIN).

• During normal operation (Mode 4, Rated speed), the Speed Setpoint Ramp is

prevented from driving the speed greater than 5294 RPM.

• During normal operation (Mode 4, Rated speed), the Speed Setpoint Ramp is

prevented from driving the speed less than 5094 RPM.




6.2.4 SP4 – SPEED DROOP This function is used to allow multiple controllers, controlling separate turbine generators

supplying a plant bus, to properly control speed if islanded, or megawatt load if paralleled with

a utility. This is done by introducing a droop into the speed measurement, prior to its use by

the speed PID function block. This block calculates the correct amount of droop, adds it to the

process measurement, and under certain circumstances, adjusts the speed setpoint. The speed

measurement and setpoint outputs of this function block are normally supplied to the speed

PID function block.

Logic

This is a standard control algorithm. It will be configured for the following:

• Pass-Through Mode: the module acts as a pass through that is, setpoints and

measurements are not modified. This mode effectively removes all droop from the

process controller.

• Speed Droop Mode: the module will run in speed droop mode. The function block

will calculate the correct value of droop based on turbine speed and add that value

to the turbine speed measurement (input SPEED). The drooped speed measurement

is available from output MEAS. It will also set the speed PID setpoint to the value of

the drooped process measurement (output MEAS) when transitions occur to make

them bumpless. The speed PID output will also be increased by the value of input

KICK whenever the controller transitions between the Pass-Through Mode and this

mode to cause the machine to pick up load following generator breaker closure.




6.2.5 SP5 – SPEED PID This is a standard PID controller. It is always enabled. The direction of controller action is set

to reverse action, which means that if the measurement increases, the PID output decreases.

Logic

This is a standard PID control algorithm. It will be configured for the following:

• Reverse Action.

• Gain on change of error

• Setpoint tracking is enabled.

• Output limits are from 0 to 100%.

• Whenever the Mode is < 4, the “start-up” Gain and Reset values are selected

• Whenever the Mode is Rated Speed or Overspeed Test, the normal Gain and Reset

values are selected.

• Whenever the Mode is Online, the online Gain and Reset values are selected.

• Whenever the Mode is Island, the island Gain and Reset values are selected.

• During normal operation (Mode 4, Rated speed) the Speed PID Controller’s setpoint

is prevented from going above 5454 RPM.

• During normal operation (Mode 4, Rated speed), the Speed PID Controller’s setpoint

is prevented from going below the rated speed (5194 RPM).




6.2.6 MW1 – SPEED SETPOINT RAMP

Ramp blocks are used to move any of the various actual setpoints to their associated target

setpoints at a steady, smooth rate.

Logic

• The Actual MW Setpoint is ramped towards the Target MW at 1.3 MW/min

• During Mode 5, Online, the MW Setpoint Ramp is prevented from driving the MW

greater than the Max MW.




6.2.7 MW2 – MW PID This is a standard PID controller. It is always enabled. The direction of controller action is set

to reverse action, which means that if the measurement increases, the PID output decreases.

Logic

This is a standard PID control algorithm. It will be configured for the following:

• Reverse Action.

• Gain on change of error

• Setpoint tracking is enabled.

• Output limits are from 0 to 100%.




6.3 TRANSMITTER FAIL-OVER STRATEGY Transmitter is considered to have failed if its reading falls below 3.2 mA (655 counts) or rises

above 21.6 mA (4423 counts) and the transmitter will remain failed unless they return to the

acceptable range and remain in this range for a period of five minutes, after which the

transmitter will be placed back into service




7 DUAL COIL ACTUATOR CONFIGURATION

A single high-current analog output supplies the signal for both coils of the dual coil actuator.

The current is divided according to the impedance of the two coils.

The power produced by the actuator coils is a function of the number of coils and the current

through them. If only one coil is used, the current must double to maintain the same power.

Because the controller output is a constant current, failure of one coil diverts all the current

through the remaining coil, thus maintaining the correct actuator output. For example: If the

controller output is 160 mA and the coil impedance is equal, the controller output is split

evenly, supplying 80 mA to each coil. If one coil fails, all of the controller output current (160

mA) goes to the remaining good coil, effectively doubling the force that the failed coil

produced before the failure.

The voltage-to-current converter across the controller output responds to changes in the

output voltage that would result from the loss of a coil. The Volt/Amp characteristics of the

good coils are programmed into the controller. A significant deviation in the volt/amp

characteristics causes an alarm to be issued.




APPENDIX A – CONSTANT LIST Constant List - Sequencing

Description Tagname Value UnitsSTG 2ND IDLE SPEED k7120IDLSPD 1000 RPMSTG 1ST IDLE SPEED WARM UP TIMER k7120IDLTMR1 34 MINSTG 2ND IDLE SPEED WARM UP TIMER k7120IDLTMR2 30 MINSTG CRITICAL SPEED BAND - LOWER LIMIT k7120CRITL 2241 RPMSTG CRITICAL SPEED BAND - UPPER LIMIT k7120CRITU 4079 RPMSTG RATED SPEED k7120MINSPD 5194 RPMSTG MAX. GOV. SPEED k7120MAXSPD 5454 RPMSTG EOST SP k7120EOST 5661 RPMSTG GOV. MOST SP k7120GOVMOST 5713 RPMSTG MAX. GOV. SPEED @ OST k7120OSMAXSPD 5750 RPMSTG FAST SPEED RAMP RATE k7120FASTRR 1000 RPM/MINSTG NORMAL SPEED RAMP RATE k7120NORRR 300 RPM/MIN

Constant List - Speed Pickup

Description Tagname Value UnitsSTG FAIL SAFE SPEED k7120FSSPD 200 RPMSTG FAIL SAFE SPEED TIMER k7120FSTMR 300 SECSTG SPEED PICKUP ENABLE SPEED k7120SPDENB 250 RPMSTG SPEED PICKUP FAILURE SPEED k7120SPDFAIL 200 RPM

Constant List - Speed Controller

Description Tagname Value UnitsSTG STARTUP SPEED CTRL. GAIN k7120SPDGAINS 2 -STG STARTUP SPEED CTRL. RESET k7120SPD_RSTS 10 REPEAT/MINSTG RUN SPEED CTRL. GAIN k7120SPDGAINR 1.5 -STG RUN SPEED CTRL. RESET k7120SPD_RSTR 5 REPEAT/MIN

Constant List - Speed Droop

Description Tagname Value UnitsSTG DROOP VALUE k7120DRP 4 %STG KICK VALUE k7120KICK 5 %STG DROOP DEADBAND k7120DRPDB 6 RPMSTG MW SPAN k7120MAXMW 30 MW




APPENDIX B – INTERFACE LIST Interface List - Buttons & Switches

S/no Description HMI DCS ESD

1 STG REMOTE/LOCAL SELECT g7120REMLOC - -2 STG TBN. START g7120HS2437A 7120-HS-2437 -3 STG IDLE SPEED SET g7120HS2435A 7120-HS-2435 -4 STG RATED SPEED g7120HS2436A 7120-HS-2436 -5 STG OVERSPEED TRIP TEST (EOST) FROM HMI g7120HS2439A - -6 STG OVERSPEED TRIP TEST (MOST) FROM HMI g7120HS2440A - -

7 STG SPEED REF. RAISE/LOWERg7120HS2431A / g7120HS2432A

7120-HS-2431 / 7120-HS-2432

-

8 STG TRIP RESET - 7120-RST -

Interface List - Lamps & Indications

S/no Description HMI DCS ESD1 STG OVERSPEED TRIP TEST (EOST) FROM HMI f7120HS2439A 7120-HS2439A -2 STG OVERSPEED TRIP TEST (MOST) FROM HMI f7120HS2440A 7120-HS2440A -3 STG IDLE SPEED SET f7120IDLSPDSET 7120-IDLSPDSET -4 STG RATED SPEED f7120MINSPDSET 7120-MINSPDSET -5 STG DROOP CTRL. SELECT f7120DRPSELECT 7120-DRPSELECT -6 STG MW CTRL. SELECT f7120MWSELECT 7120-MWSELECT -

Remarks: Only signals 7120-HS-2431 and 7120-HS-2432 are hardwired signals. The rest are soft-link signals.




APPENDIX C – ANALOG INPUT RANGES

Analog Input Range

S/no Description Tagname Min Range Max Range Eng. Unit1 STG GEN. MW 7120-MW-2401 0 30 MW2 STG REMOTE MW 7120-MW-2402 0 30 MW




APPENDIX D – APPLICATION DETAIL

Application Details - SpeedInput:S/no Tagname Description Remark

1 p7120SE2401A STG TBN SPEED PROBE A2 p7120SE2401B STG TBN SPEED PROBE B3 p7120SE2401C STG TBN SPEED PROBE C4 k7120FSSPD STG FAIL SAFE SPEED5 k7120FSTMR STG FAIL SAFE SPEED TIMER6 k7120SPDENB STG SPEED PICKUP ENABLE SPEED7 k7120SPDFAIL STG SPEED PICKUP FAILURE SPEED

Output:S/no Tagname Description Remark

1 r7120SPEED STG ACTUAL SPEED2 r7120PEKSPDREC STG PEAK SPEED RECORDER3 r7120TRPSPDREC STG TRIP SPEED RECORDER

Application Details - Speed PIDInput:S/no Tagname Description Remark

1 r7120SPDSPA STG ACTUAL SPEED SP2 r7120SPEED STG ACTUAL SPEED


1 r7120SPDOUT STG SPEED PID OUTPUT

Application Details - MW PIDInput:S/no Tagname Description Remark

1 r7120MWSP STG MW SP2 TBD STG GEN. MW


1 r7120MWOUT STG MW OUTPUT

TS3000

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