CAPITULO 8 MANUAL TREND 60 WLE

TRENT 60 WLE POWER GENERATION PACKAGE SET TRAINING MANUAL

PACKAGE CONTROL SYSTEM 8

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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.


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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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



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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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.



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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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)



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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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



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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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.



FIG 1 BLOCK DIAGRAM OF CONTROL SYSTEM



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FIG 2 CONTROL SYSTEM CONCEPT



FIG 3 PCS/ECS BREAKDOWN



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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



FIG 4A TYPICAL HMI SCREEN



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FIG 4B TYPICAL HMI SCREEN



FIG 4C TYPICAL START HMI SCREEN



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FIG 5 SYSTEM ARCHITECTURE

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FIG 6 PCS/ECS INTERFACES

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FIG 7 TYPICAL TRENT WLE CONTROLS PROCESS

FT125

FT125



FIG 8 CONTROL CABINET



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FIG 9 PROGRAMMABLE LOGIC CONTROLLERS



FIG 10 SHUTDOWN RELAY AND SWITCHES



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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

CAPITULO 8 MANUAL TREND 60 WLE

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