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2 Retrofitting Steam Turbines
2 Retrofitting Steam Turbines
Ronald Hitzel
Global Business Development Manager
Instrumentation & Controls
Siemens Westinghouse Power Corporation
Fred Block
I&C Engineer
Siemens Westinghouse Power Corporation
Ronald Hitzel
Global Business Development Manager Instrumentation & Controls
Siemens Westinghouse Power Corporation
4400 Alafaya Trail, MC 250, Orlando, FL 32826-2399
Telephone: (407) 736-2553; Fax: (407) 736-5025; E-mail: ron.hitzel@siemens.com
Fred Block
I&C Engineer
Siemens Westinghouse Power Corporation
1345 Ridgeland Drive, Suite 116, Alpharetta, GA 30004
Telephone: (678) 256-1606; Fax: (678) 256-1558; E-mail: fred.block@siemens.com
Introduction
Better performance throughout the steam turbines operational life improves cost
efficiency. Today, better control is even more important then before, as older turbines
operate beyond their original life expectancy. Since the early 1980s digital controls
have been the accepted standard in many North American and European
manufacturing and process industries. Recent developments in digital processing
technology (i.e. faster processing speeds, lower cost, and smaller sizes) make digital
turbine control the preferred technology of power plant operators.
Traditional steam turbine controls were accomplished with a fly-ball governor for
speed indication, mechanical linkages, and low-pressure turbine lube oil. Although
these systems are fairly reliable, they are becoming costly to maintain, as many of the
original control devices are now obsolete. Replacement parts, if available, are becoming
expensive with long delivery times. Maintenance of these systems required a certain
degree of familiarity and knowledge of the instrumentation of its era. The knowledge
base involving implementation of controls on mature steam turbines has diminished
over the years, which directly affects unit availability and reliability.
Turbine Control Philosophy
The modern digital turbine control system (TCS) is designed to control the main
steam flow to the steam turbine in all operational conditions by means of the turbine
throttle, governor, admission, and or extraction control valves. The control functions are
conducted through the use of simplex or redundant electronic functions incorporated
within the TCS software and hardware, integrated through the use of servo coil
actuators.
Speed Control
Load Control-via either a load setpoint command from a DCS, or can be configured
to receive MW input for utilization of the load control function developed within the
system, or can be configured stand-alone as a MW or Speed Droop function.
Frequency Influence
The TCS system ensures stable operation throughout all operational phases, i.e.
during unit start up, shutdown, parallel operation, Island mode, etc. In generation
applications, full load rejections created by a sudden separation from the grid (lightning
strike in the field, etc.) are controlled through the TCS thereby preventing an over-speed
condition and collateral damage from occurring.
Within the standard design of the TCS system, individual device inputs within the
master controller algorithms developing a 1 of 2, 2 of 3, and or 2 of 4 cross configuration
voting functions can be deselected through the use of an optional password protected
engineering client/server Operating Terminal (OT) station. In certain critical systems,
automatic de-selection is implemented upon a loss of the device-input signal, with the
system automatically returning to a normal state upon correction of the issue. What
this means is that the system senses each device input signal, monitoring it for quality,
in the event the device input falls outside of the pre-selected, configurable threshold (for
example, one of the active speed pick-ups just failed high), then the device is removed
from its associated algorithm. An alarm is issued, alerting the operator of the device
malfunction, and the control algorithm automatically transfers to the next assigned
device redundancy level. Upon correction of the malfunction, the control system will
automatically transfer to the next device redundancy level to ensure the maximum
availability and protection of the system.
The TCS should provide automatic and manual shutdown. In automatic
shutdown, the system must lower the load until the generator breaker opens on reverse
current. On manual shutdown, the operator will open the generator breaker manually
once the turbine is at minimum load.
The TCS Software System Comprises the Following Standard Master Controllers:
1. Speed Control
The speed control function provides the operational control involving the speed
limiting and acceleration functions of the unit over the entire operating speed range.
The speed control system is fully integrated with the load rejection and load anticipatory
functions as required, as well as the turbine trip system. The speed control function is
designed to receive up to three speed inputs. These inputs feed a 1 of 2, 2 of 3, and or
2 of 4 voting algorithm which issue an overspeed trip command. If one of the channels
fail, that channel is automatically deselected, an alarm is issued alerting the operator of
the malfunction, and the unit shifts to the next available comparison algorithm. In the
event the speed channel is repaired (the operator found a loose wire connection in the
junction box on the ST), then the unit automatically detects the correction, and shifts
back automatically into the pre-configured algorithm.
In generation applications, when the generator is on the grid and the turbine
controller is in the load control mode, the speed control function continues to provide a
speed error (influence) input for use in frequency regulation. Comparing the speed
reference with the actual speed derives the speed error signal. The frequency detection
accuracy is within 10 mHz, with tunable variables controlling deadband and droop
characteristics.
The desired speed reference is selectable manually from the client Operating Station
(OS). The speed acceleration rate (ramp rate) can be selected either manually or
automatically through the client OS station. Proportional speed regulation,
acceleration/deceleration ramp rates, and turbine/boiler runback functions are entirely
configurable through the Engineering Station (ES). Discrete values are provided for
selecting steady state operation at lower speed holds, as well as for operation at rated
speed. Four predominant modes of start-up while under speed control are provided as
standard solutions within the TCS system:
A speed setpoint is keyed into the system via the client OS, and the operator hits
go, and the unit ramps at a pre-determined ramp rate (which is programmable via
password protection) to the desired setpoint and holds at the selected value until
another command is issued.
The operator manually raises and lowers the speed via a soft-key selector (up or
down gradient key). In this function, if the operator selects a stop function during a
transient condition through the predetermined critical bands, the unit will continue to
either increase or decrease to the next available threshold. What this means is that if
the operator is telling the unit to ramp up, and then stops the command during a
critical state, the unit will not stop until after achieving the high end of the critical range.
The same occurs during a downward gradient change.
Depending on the particulars of the steam turbine itself and its application use, the
unit can be configured to open the governor valve(s), and modulate the stop valve in
order to warm the unit without breaking turning gear speed. After the unit has gone
through its initial thermal soak period (which can be configured via either thermal
inputs-RTDs/Thermocouples or via a time-based sequence), the stop valve will
continue to open, bringing the unit up to the minimum governor speed (typically 95%
rated speed/synchronous speed). This function is completely programmable and
generally depends on specific unit requirements. At this point in time, the unit will bring
the Governor Valve down below the Stop Valve (in order to shift the control from the
stop valve- full arc, to the governor valves-partial arc control), and issues a synch
command enable, facilitating generator breaker closure.
Another standard function utilized by many customers to facilitate automatic start-up
is the configuration of the system according to the units Standard Operating Procedure.
Each unit is issued with a Standard Operating Procedure (SOP), which typically is
modified in writing and issued by the customer as the operations guide governing the
machine. The vendor provides for configuration of the unit to operate based on the
time- based sequence issued under the SOP. In other words, the unit would be ramped
to a pre-determined setpoint, held at that point on a timer, and then ramped to the next
point and so and so forth. At no point would the unit be allowed to stop within the
critical bandwidths.
The TCS employs a configurable, operator controllable, proportional regulation
controller to ensure a bumpless transfer from full arc and partial arc admission.
A separate function is employed which, when password enabled through the
Engineering Station (ES), enables a manually controlled overspeed test. Configurable
acceleration rates and gradient ceiling facilitate controlled testing of the mechanical
overspeed protection devices. In the event the unit reaches the gradient ceiling prior to
the units mechanical devices activating, or the operator disables the function, the unit
will automatically coast down to rated speed.
Upon achieving synchronous speed, the controller accepts raise and lower impulses
from the auto synchronization circuitry. Standard provisions are made within the TCS to
facilitate the incorporation of both manual and automatic command and control.
A load limiter is embedded within the load control function to limit the steady state
opening of the control valves thereby limiting the flow of steam to the turbine. The load
limit function interfaces to the runback function so that an adjustment of the load limit
automatically causes a runback of the load reference setpoint to a level 2% above the
predetermined load limit. This desirable function prevents a sudden increase in load
when the load limiting function is corrected (for example; the boiler feed water pump
circuit breaker was inadvertently turned off, and has been re-energized). The load limit
is configurable through the entire range of operation via password protection. The TCS
is designed to provide an indication of deviation percentage from the load limit and
issue an indication when the load limit is activated.
A load rejection occurs when the generator breaker opens at load. This situation
should be handled by the TCS by rapidly shutting the governor valves thereby
minimizing the pending overshoot. This is an anticipatory function triggered by the
generator breaker position indication. The governor valves then reopen to achieve preconfigured load rejection speed.
A megawatt (MW) feedback loop embedded within the TCS load control function
which automatically adjusts the megawatt reference setting to correspond with the
actual real load (MW). Through selection of this control loop function through the client
OS, the MW error value developed between the relationship of the corrected reference
MW and the actual MW is applied to a PI controller, which will automatically adjust the
control valve signal to reduce any MW deviation.
An initial load pickup (Min-load) function embedded within the TCS load control
function provides a configurable (typically 3-5%) step increase that occurs each time the
generator is initially synchronized to the grid. This Min-load function is used during
initial loading of the machine in order to prevent reverse power conditions upon synch
enable and is configurable through password protection at the Engineering Station (ES).
An impulse pressure feedback loop is embedded within the TCS load control
function to correct the megawatt reference versus the actual megawatt value based on
actual Impulse pressure. The impulse pressure error derived from the corrected
reference impulse pressure (in MW units) and the actual impulse pressure is applied to
the controller, which will trim the control valve signal to reduce any impulse pressure
error.
4. Turbine Stress Influence
The TCS system is designed to accept influencing from a turbine stress evaluation
(TSE) system thereby limiting the acceleration and load ramp gradients. During start-up
and shutdown, a TSE would provide an input generated from the algorithm delta
created between two thermocouples embedded within the main stop valve (MSV or
throttle valve) and main control valve (MCV or governor valve). This value would limit
the acceleration and or deceleration limit applied to the turbine via the master
controllers. Under normal loading operations, a TSE would provide an input generated
from the algorithm delta created between thermocouples embedded within the casing
(typically HP and IP, which can be utilized to generate a HP/IP shaft deviation
algorithm). This deviation signal is utilized within the master controllers to limit the load
gradient applied.
5. Frequency Influence
When the generator is on the grid and the turbine controller is in the load control
mode, the speed control function continues to provide a speed error (influence) input for
use in frequency regulation. Comparing the speed reference with the actual speed
derives the speed error signal. The frequency detection accuracy is within 10 mHz, with
tunable variables controlling deadband and droop characteristics.
6. ADS (Automatic Dispatch System) Influence
The TCS system is designed to accept influencing from an ADS controller, facilitating
the remote dispatch loading and unloading of the machine along predetermined ramp
gradients. The load limit gradients are configurable through the entire range of operation
via password protection.
7. Valve Lift Control
The valve lift controller integrates the min-gated valve demand reference versus
valve actual (setpoint) functions. Some vendors have standard applications oversampling rates of greater than 20 samples per cyclic event throughout the stroke of the
valve to achieve the fastest possible response time.
The Turbine Control System (TCS) Processor
The brain of the steam turbine controller should be a high-speed digital processor.
One example is the S7 Programmable Logic Controller. The S7-416 is a high availability
processor with the performance required for applications such as steam turbine control.
It acquires measured values and status signals from the I/O, carries out open- and
closed-loop control functions, transfers the resulting commands to the I/O and performs
all the functions of the group and individual device levels. Clearly structured and
vigorously tested control concepts should be available for various configurations of plant
control tasks. One example of a specific application would provide a modular-based,
fan-free, cost-effective solution with a high degree of expansion and communication
options. This user-friendly system provides for the easy implementation of distributed
structure that is capable of handling the most sophisticated tasks in the high-end
performance range. In your application, this processor will automate the total turbine
package.
Look for a vendor to configure the TCS to allow push button valve calibration and
tuning. This significantly reduces commissioning and startup times. Operating alarms
and trends should be easy to see and configure in the TCS operator interface graphics.
A trip-reset input is necessary to clear any latched trips. The trip output of the TPS
consists of six- (6) discrete outputs, two- (2) from each processor. This matches the
six- (6) emergency trip oil dump solenoids configured in a 2-out-of-3 to trip
arrangement.
Field Device Parameter Sensing Assemblies
This instrumentation upgrade is a 2-out-of-3, 2-out-of-4 voting design. Each transmitter
has a local LED readout, and is plumbed with an isolation valve and calibration port.
The transmitters are pre-wired to an on-board junction box with ring lug terminal strips.
This proposal includes 2-out-of-3 sensing assemblies for the following functions:
The following items are installed in place of the trip block assembly and provide inputs
to the TPS.
Vacuum Pressure. The new panel has three- (3) vacuum pressure measurement
devices that provide discrete contacts and analog 4-20mA signals. They may be
connected to the TPS as either. Upon sensing a high exhaust pressure (low
vacuum) the TPS will issue a trip command.
Bearing Lube Oil Pressure. The new panel has three- (3) pressure measurement
devices that provide discrete contacts or analog 4-20mA signals. They may be
connected to the TPS as either. Upon sensing a low bearing oil pressure the TPS
will issue a trip command.
Turbine Thrust Pressure Sensing. While retaining and monitoring the existing oil
pressure based thrust-sensing system, this modification incorporates four- (4)
independent, pressure measurement devices that provide discrete contacts or
analog 4-20mA signals. Two- (2) of the transmitters facilitate monitoring of the
active thrust position, and two- (2) of the transmitters facilitate monitoring of the
inactive thrust position. The transmitter outputs may be connected to the TPS as
either discrete contacts or as 4-20mA signals. Upon sensing turbine thrust the TPS
will issue a trip command.
Turbine Trip Solenoids. This modification incorporates the installation of three- (3)
new sets of turbine trip solenoids to facilitate a 2-out-of-3 voting algorithm within the
TPS system functionality. Included within this modification is the Auxiliary Governor
Function, which will consist of a single set of solenoids. A manual trip handle (Local
E-Stop) with an associated limit switch is provided for a local hand trip function.
Simplex discrete output generated by each TPS processor in a 2-of-3 algorithm for
the Auxiliary Governor solenoid function. A set of solenoids that is in same
configuration as the turbine trip solenoids.
Tests are conducted from the DCS via a communication link or locally via the HMI.
Speed Sensing
The Magnetic Pick Up (MPU) bracket provides for primary speed control and electronic
overspeed protection will be designed to incorporate multiple new speed probes. Within
the confines of a base scope of supply, the vendor should provide four- (4) new active
magnetic speed probes for software based zero speed detection, measurement, and
overspeed protection.
Three- (3) of these probe slots are dedicated for software overspeed measurement
and protection.
Three- (3) of these probe slots are dedicated for hardware overspeed protection.
Two- (2) of these probe slots are dedicated for installed spares.
Zero speed detection is accomplished directly through the use of the installed
software based system.
The system senses turbine speeds from 0 rpm through overspeed. All inputs are
individually processed through a 2 of 3 algorithm-generating outputs to perform speed
control functions as well as overspeed trip functions utilizing a field proven MPU voting
scheme. The overspeed trip function will be implemented within control logic and
becomes the primary form of overspeed protection.
Trip plunger improperly machined, a grooved finish on the bore of the plunger guide
bushing
The end of the plunger was flared out preventing the trip plunger from moving. This
was the result of a millwright physically pushing on the end of the plunger with a
center punch.
The installed spring was too weak from either an old spring that had lost some of its
force or a spring with too low a spring constant.
For the purpose of vibration monitoring, a system to monitor the status of the
bearings should be made available. It should provide highly reliable turbomachinery
information for improved protection. The system should continuously measure and
monitor a variety of parameters, which are vital to turbine protection. When any of
these parameters begin to indicate weakness in the turbine components, such as
imbalance, bearing failures, misalignment, and shaft crack conditions, the operator
should be alerted. Engineering information should be provided that includes mechanical
modification instructions to install probes in the turbine.
The communications to the existing DCS should be a non-proprietary open protocol.
Many plant sites have multiple protocols that increase maintenance. The ability to
communicate with one common protocol to devices such as generator protective relays,
automatic voltage regulators, Turbine Stress Evaluator, vibration monitoring, etc will aid
operations and maintenance capabilities.
It would be prudent for a customer to chose a vendor that can provide all of the
basics plus auxiliaries utilizing a common control platform. This includes generator
protective relay and automatic voltage / excitation systems. Having systems that
communicate with the same protocol and contain similar hardware will reduce
operating, training, and maintenance costs.
Conclusion
Because of their age, design, and lack of maintenance, todays steam turbine
governor control systems are operating in a manner far different than the original
manufacturers designed them. They are also operating in an order of magnitude less
efficient in performance than that of similar sized turbines operating with the latest
digital controls. Typically these older steam turbines drift, control has a sluggish
response caused by multiple individual servo motors connected by antiquated linkages
and connectors, or does not operate in a coordinated fashion. These problems are
costing your operation and maintenance teams time and money better spent on
improving the operation rather than just keeping it running. Find a vendor that can
implement an innovative solution for modernizing your steam turbine controls and that
can integrate this upgrade into your current or future plant systems using a scalable,
standardized, proven platform. Upgrading to a state-of-the-art turbine control system will
generate true long-term benefits for operations, maintenance, and service of your steam
turbine.
References
API Standard 612, 1995, Special Purpose Steam Turbines for Petroleum, Chemical,
and Gas Industry Service, Fourth Edition, American Petroleum Institute, Washington,
D.C.
API Standard 670, 2000, Vibration, Axial-Position, and Bearing Temperature
Monitoring Systems, Fourth Edition, American Petroleum Institute, Washington, D.C.
Clark, E. E., 2002, Steam Turbine Overspeed Incidents, The Hartford Steam Boiler
Inspection and Insurance Company.
Rutan, C.R., 2003, Turbine Overspeed Trip Protection, Lyondell/Equistar Chemical,
LP, Proceedings of the Thirty-Second Turbomachinery Symposium.
Clark, B.E., 1992, Steam Turbine Generator Equipment Westinghouse Electric
Corporation.
Simatic Catalog ST 70, 2000, Components for Totally Integrated Automation,
Siemens.