GAZA POWER GENERATION COMPANY 140MW CCGT POWER … SOP-012-DCS(R5).pdf · System Startup ... Plant...

GAZA POWER GENERATION COMPANY 140MW CCGT POWER PLANT

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SOP: 012 REVISION 5 SECTION: DISTRIBUTIVE CONTROL SYSTEM (DCS)

GPGC SOP-012 of 44 JAN, 2010

1 SAFETY …………………………………………………………………………….. 3 2 SYSTEM DESCRIPTION ………………………………………………………….. 4 2.1 Function ……………………………………………………………………… 4 2.2 Description …………………………………………………………………... 4 3 BLOCK 10 CONTROL …………………………………………...…….………….. 9 3.1 Advant Controller 450 “AC450 “ …………………………………….…….. 9 3.2 Distributed “S800 “I/O Station ……………………………………..………. 10 3.2.1 Electrical Building near Workshop ………………………….….. 11 3.2.2 HRSG 11,13,22,24 ………………………………………...…….. 11 2.4 Block #2 Control …………………………………………………………….. 12 4 BLOCK 20 CONTROL …………………………………………...…….………….. 12 5 CENTRAL CONTROL ROOM “CCR “ ………………………………………….. 13 5.1 Advant Station OS520 ……………………………………………………… 14 5.2 Alarm and Event Printers ………………………………………………….. 14 5.3 Hardcopy Printers ……………………………………….………………….. 14 5.4 Advant Station 130 “Engineering Station AS130 “ ………………...……. 15 5.5 Data Storage System DSS ………………………………………………… 15 5.6 Block Allocation of Equipment in CCR …………………………………… 15 6 GENERATING UNIT GT13 ………………………………..……………………… 16 6.1 Advant Controller 450 “AC450 “ …………………………………..………. 16 6.2 Advant Controller 160 “AC160 “Protection ………………………..……... 17 6.3 AC160 Turbine Controller …………………………………………….……. 17 6.4 Advant Controller 110 “AC110 “Voltage Regulator ………………..……. 18 6.5 Advant Station OS520 ……………………………………………………… 18 7 GENERATING UNIT GT11 ……………………………..………………………… 20 8 GENERATING UNIT GT22 ………………………..……………………………… 20 9 GENERATING UNIT GT24 ………………………..……………………………… 20

10 GENERATING UNIT ST10 …………………………...…………………………… 21 10.1 AC160 Protection ……………………………………………….………….. 21 10.2 AC160 Turbine Controller ……………………………………….…………. 21 10.3 Distributed I/O Rack “S100 I/O “ …………………………….……………. 22

11 GENERATING UNIT ST20 ………………………...……………………………… 23 12 LOCAL CONTROLLER “PLC “IN PACKAGE SYSTEMS ……………….…… 24


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13 CLOCK SYNCHRONIZATION …………………………………………………… 25 14 DCS OPERATION ………………………………….……………………………… 26 15 SINGLE FAILURE CRITERIA …………………………………………….……… 31 16 SELF- DIAGONISTIC ………………………………………………………...……. 34 17 PROCESSOR AND BUS LOAD, SPARE CAPACITY ……………..……..…… 35 18 SYSTEM OPERATION ……………………………………………………………. 36 18.1 Normal Operation Valve Alignment List ………………………………….. 36 18.2 Normal Operation Power Supply List ……………………………………. 36

18.3 System Prerequisites ………………………………………………………. 36

18.4 System Startup ……………………………………………………………… 36 18.5 System Normal Operation …………………………………………………. 37 18.6 System Shutdown ………………………………………………………….. 37

19 INSTRUMENTATION / ALARMS ………………………………………………… 38 19.1 I&C Matrix ………………………………………………………………….. 39 19.2 Fault Procedures ……………………………………………..…….………. 39

20 SYSTEM HISTORY ………………………………………………………………… 39 21 SYSTEM MODIFICATIONS ………………………………………………………. 40 22 SYSTEM UNTREATED MALFUNCTIONS ………………………………………. 41 23 SYSTEM LAYOUT …………………………………………………………………. 42 24 HAZOP METHODOLOGY ………………………………………………………… 43 24.1 Risk Matrix …………………………………………………………………... 44 24.2 HAZOP Matrix ………………………………………………………………. 46

25 REFERENCES ……………………………………………………………………… 47


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1 SAFETY Prior to operating the Distributive Control System ( DCS ) owners, employers and users should familiar with, and comply with , all applicable regulations and any other applicable local codes, standards and regulations relative to personal protective equipment. This includes eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremities, protective clothing, protective shields/barriers and electrical protective equipment as well as noise exposure administration and/or engineering controls and/or personal hearing protective equipment.

• The Distributive Control System contains a potential hazard for shock or burn. Only

personnel who are trained and thoroughly familiar with the equipment should operate or maintain the equipment.

• To minimize the hazard of electric shock or burn, an approved grounding practices must

be strictly followed. • Follow all guidelines outlined in the safety Manual to prevent equipment damage or

personnel injury. • Prior to performing any maintenance on the system obtain the proper personnel

protection equipment against electrical shock/burns.


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2 SYSTEM DESCRIPTION

2.1 Function

The function of the DCS is to provide process monitoring, controlling, general purpose computations and analysis, and man/machine interfaces for the operation of Gas and Steam turbines, generators, auxiliary equipment and balance of plant (BOP) systems.

2.2 Description

The DCS is a network of computers put together by instrumentation and control engineering technology systems. It is of fabricate ABB and consists of units from the Advant OCS family. Advant OCS is an open, integrated, and distributed system for industrial automation. It consists of computer based units and various communication options including field buses and local and wide area networks. These combine effectively to form powerful automation systems, which can be used in application ranging from small machine control to total plant wide automation. The combined cycle plant is equipped with the powerful ABB Advant OCS process control system. The system provides reliable control, protection and monitoring of this combined cycle power plant. The equipments of the system are standardized for the whole plant, which will reduce the spare parts and rationalize operation and maintenance. The complete power plant (Power Island & all BOP systems) can be monitored and controlled from central control room. The GT’s are provided with local control interface equipment (20” CRT operator stations, printer, hard copier, and DAT recorder) so that they can be operated locally as well as from central control room. In the central control room, four single CRT based operator station are provided. These stations can be used as operator, engineer, or supervisor station. A total of two optical disk (one per power block) system will be provided. All the power generating units in the plant are connected to each other and to the operator stations in the control room by a central network. The control network is based on a redundant Master Bus 300 (MB300); it is a high performance serial synchronous half-duplex bus for medium communication distances. The MB300 is connecting all the generating units' main controllers, Advant controller 450 “AC450” and the block controllers AC450 to each other. The MB300 is also


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making it possible for the operator stations 520 “OS520” to communicate with the signals in the AC450. The MB300 redundancy network numbers are Net 11 and Net 12. From a functional viewpoint, the redundant networks work in a hot standby implementation. This means that the primary network has the communication responsibility. The secondary network stands by to automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action. In the standby mode of operation, basic messages for diagnostics are continuously sent and received. The control network is performed by optical fibers and a star coupler that is power supplied from redundant 230 VAC UPS. This secures that a network fault in one plant block # 1 not affecting the other plant block # 2.


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3 BLOCK 10 CONTROL 3.1 Advant controller 450 “AC450”

This equipment located in the control equipment room block # 1.

The AC450 computer keeps the application software program for the following: Plant load control, Plant main sequence, Block sequence, Unit sequence, Main Cooling water system, Closed cooling water system, External liquid fuel, Water treatment system, Main steam system, Condenser system, Condenser evacuation system, Drain system, Condensate system, Compressed air system, HRSG system, Feed water system, Steam turbine system for ST10, Low voltage switchyard 0,4 KV, Medium voltage switchyard 6.0 & 11.0 KV, High voltage switchyard 220 KV.

Controller includes the main following parts: 1) Basic unit, comprising CPU and rack with back plane bus. 2) Communication boards. 3) I/O boards.

1) Basic unit. The basic unit is an AC450 equipped with the latest function library available. Redundant microprocessor is used as a backup to normal pre selected microprocessor. At indicated fault in the pre selected microprocessor, the redundant microprocessor will take over control. This take over is made bumbles without any manual action. CPU and memory board type PM511V08.

2) Communication boards.

- Boards for MB300 communication between AC450s and OS520s. Redundant communication board and cable are used. From a functional viewpoint, the redundant networks work in a hot standby implementation. This means that the primary network has the communication responsibility. The second network stands by to automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action. Communication board type CS513.

- Board for Advant Field bus 100 “AF100”. It is the local control network between AC450 and the Steam Turbine two AC160. Decentralized I/O stations “S800” are also used connected to the AF100. A modem TC516 is also used in the AC450 end. Redundant communication board and cable are used. The redundant local control networks work in a hot standby implementation, where the primary network has the communication responsibility and the secondary network stands by to automatically


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take over in case of fault in the primary network. This take over is made bumbles without any manual action. Communication board type CI522.

- Board for GCOM: 1. GCOM communication board and cable are used for communication with a PC-based Data Storage System (DSS). There is one GCOM pro Controller AC450 communicating with one OPC Server on each of the two blocks. There is no redundancy for the GCOM communication board. 2. GCOM communication board and cable used for communication with the switch-yard, Gaza West S/S Operator Station GCOM DDE-server. From the switch-yard Operator Station are measurements and breaker status transmitted to the AC450 of block 1.

3) I/O boards. The I/O boards are divided into: - Analogue inputs placed in “S100” I/O sub rack. - Analogue outputs placed in “S100” I/O sub rack. - Digital inputs placed in “S100” I/O sub rack. - Digital outputs placed in “S100” I/O sub rack.

For types and quantity of I/O boards refer to circuit diagram 2450 010.

The controller is powered up from redundant 230 VAC UPS supplies, one from each block.

3.2 Distributed “S800” I/O Stations

3.2.1 Electrical building near workshop

One S800 I/O station is placed in electrical building near workshop. There will be hardwired 230V AC digital signal exchange to the equipment placed in the onshore pump house. This station handles I/O signals for this area of the plant for example: Raw cooling water, Main cooling water system, External liquid fuel system.

Main parts included in this station: 1. Communication boards. 2. I/O boards. 1) Communication boards Redundant communication board and cable are used for Advant Field bus 100 “AF100 “, where the redundant local networks work in a hot standby


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Implementation. This means that the primary network has the communication responsibility and the secondary network stands by to automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action. Communication board type CI820. 2) I/O boards The I/O boards are divided to: - Analogue inputs. - Analogue outputs. - Digital inputs. - Digital output.

For types and quantity of boards see circuit diagram 2450 010. This station is powered from redundant 230VAC UPS supplies, one from each block.

3.2.2 HRSG 11,13,22,24

One S800 I/O station is placed at HRSG11/13/22/24, this station handles I/O signal for this area of plant. The main parts of this station are: 1. Communication boards. 2. I/O boards. 1) Communication boards. Redundant communication board and cable are used for Advant Fieldbus 100 “AF100 “. The redundant local control networks work in a hot standby implementation. This means that the primary network has the communication responsibility, and the secondary network stands by to automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action. Communication board type CI820. 2) I/O boards. The I/O boards are divided to: - Analogue inputs. - Analogue outputs. - Digital inputs. - Digital outputs. For types and quantity of boards see circuit diagram 2450 010. This station is powered from redundant 230VAC UPS supplies, one from block.


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4 BLOCK 20 CONTROL

The equipment for block 20 is identical as for block 10 with following exception: Block 20 has only limited functions for plant overall control. Process systems common for block 10 and block 20 has all single signals connected to the Block10 controller. In case of failure of block10 controller, some of the most important signals needed for running redundant components for serving block2 units are connected to block 20 controller.


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5 CENTRAL CONTROL ROOM “CCR “

Equipment in central control room:

5.1 Advant Station OS520

The first set of OS520 computer is a Hewlett Packard operator station with UNIX operative system. The system consists of a workstation with 256 Mbytes RAM, 9 G bytes hard disk, operator keyboard, mouse and colour graphic monitor 21’’.

The operator station has TCP/IP connection and software for the following:

- Displays for all Generating Units, BOP and Process system. - Displays for logged signals. - For each AC450 controller a limited value of tag no can be selected for regular

sampling and stored for a short time for presentation in a short time trend curve. - Standard/objective displays for each tag are available. - Process Alarm and event list presentation. - DCS alarm list. - The system is self diagnostic and all disturbances are shown on a special display

page called system alarm page. - Presentation of control system status. - Presentation of trend curves. - Presentation of tags which are sampled in a log table.

When the station is used as an engineering station there are two main functions:

1) Configuration of operator displays

Operator displays are configured with the display configuration tool. Configured displays can be dumped to the DAT recorder for loading on the 7 other Operator stations in the plant. Displays stored on DAT tape can be loaded from DAT recorder. The station can transfer configured displays through the TCP/IP net to the 3 others Advant Operator Stations placed in CCR with installed client software, whereas the Advant Station described here has the server software. Although there is only one Advant Station that has the server software installed it does not have any impact on the plant availability. Server down-loading of displays is a off-line procedure done after engineering work with display modifications as DAT tapes are always possible to use for back-up and transfer of the displays.


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2) Configuration of AC450 application program

Modification of the application programs for all AC450 can be carried out with the Online Builder tool.

The other three OS520 computers have the same properties as mentioned above.

5.2 Alarm and Event Printers

Four sets of Matrix printers are used for alarm and event list. Connection to operator station is with RS 232C. The events are divided so that block 10 events are on printers 1& 2 and block 10 events are on printers 3 & 4.

5.3 Hardcopy Printers

Two sets of hardcopy printers are used for copying process displays, alarm list printout, event list printout, trend curves printout and log pages printout. Any of the operator stations in CCR can use the hardcopy printer through the TCP/IP net.

5.4 Advant Station 130 Engineering Stations “AS130 “

Two sets of AS130 stations having everything necessary for configuring and programming of Advant OCS systems are ready to be used. Connections are made locally to actual target system. They contain the tools and the necessary hardware for configuration, application building, fault tracing, documentation, testing and commissioning of the following target systems:

- Advant Controller 100 series. - Advant Controller 400 series.

AS130 Engineering Station is based on an IBM PC-compatible personal computer, suitable for use in industrial environment and satisfies the Advant OCS environmental immunity specifications and safety standards. It includes Windows NT 4.0 operating system and the corresponding manuals. AS130 stations are equipped with an active 12.1” Thin-Film Transistor colors display, a Pentium 120 MHz CPU, a 2 Gbytes hard disk, and 32 Mbytes RAM. The AS130 station is the only Engineering station to handle the AC110/AC160.

AC110/AC160 couldn’t be handled with the Engineering tool in the OS520.


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5.5 Data Storage Station DSS

The DSS is a basic PI system and it consists of a PI server with six interfaces. Operators use Process Books (PB) to read collected history and real-time values. The information flow goes from the control system to the PI server and from PI-server to Process Book. The PI interface system consists of, except for the interface, two PI API nodes. An API node is a PC with Windows NT Workstation, PI, API software and interfaces. The API node communicates with the control system and sends data to PI server. The DSS system includes software for:

- Long (1-year) and short term (35-days) data storage. - Retrieving of data, event recording, logging and trending of selected

points of data. - Displays for logged signals. - Presentation of trend curves. - Automatic generated reports. - Programmable report functions. - Reports in Excel format. - Storage of data on optical disc.

5.6 Block Allocation of Equipment in CCR

All units can be operated from each OS520 but the equipment will be divided for the two blocks of the plant. The following list of equipment exists in the CCR for each block:

- Two sets of Advant Station OS520. - Two sets of Matrix Printers. - One set of Hardcopy Printers. - One set of Advant Station 130 Engineering Station AS130.

The two Advant Station allocated for the block will have quick access to the displays useful for operation of the block. The alarm/event list will include events relevant for the actual block. There is one set of Laser Printer common for both blocks. It is used for documentation of application software for all Controllers. It must be manually connected to the OS520 or AS130, which used for the actual printout.

The equipment allocated for block 10 will be powered from block 10 230VAC UPS, equipment allocated for block 20 will be powered from block 20 230VAC UPS.


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6 GENERATING UNIT GT13

For detailed information about the GT equipment see the following GT documentation: Protection system description, drawing no 3813 375. Turbine governor system description, drawing no 3813 373. Computer system description, drawing no 3813 374. All equipment are powered from 230VAC UPS, and located in GT local control compartment.

6.1 Advant Controller 450 “AC450 “

AC450 computer keeps the application software for controlling and sequencing of GT and handles all measurements of electrical signals and orders for MCC. It includes the following main parts:

1) Basic unit, comprising CPU and rack with back plane bus. 2) Communication boards. 3) I/O boards.

6.1.1 Basic Unit:

The basic unit is an AC450 equipped with the latest functions library (PC- elements) available. Redundant PM511 microprocessor is used for hot standby take over control.

6.1.2 Communication Boards:

Communication board type CS513 for MB300 to connect AC450 to OS520. Communication board type CI523 for AF100 to connect AC450 to AC160/AC110. Redundant communication boards and cables are used for hot standby take over communication.

Note that AF100 is the local control network between AC450 and the Advant ControllerAC160s and AC110.

6.1.3 I/O Boards:

For I/O boards types see GT documentation. There are other types of cards used for GT application compared with BOP application.


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6.2 Advant Controller 160 “AC160 " Protection

AC160 computer keeps the application software for channel 1 of the protection system. It includes the following main parts:

1) Basic station, comprising CPU and rack with back plane bus. 2) Communication boards. 3) I/O boards.

6.2.1 Basic Station:

The basic unit is an AC160 equipped with the latest function library (PC-

element) available. Redundant PM645 microprocessor is used for hot standby take over control.

6.2.2 Communication Boards:

AF100 redundant CI630 communication board and cable are used for hot standby take over communication.

6.2.3 I/O Boards:

For I/O boards types and quantity please see GT documentation.

6.3 AC160 Turbine Controller

AC160 computer keeps the application software for turbine controller and channel 2 of the protection system. It includes the following main parts:

1) Basic Station, comprising CPU and rack with back plane bus. 2) Communication boards. 3) I/O boards.

6.3.1 Basic Station

The basic unit is an AC160 equipped with the latest PC-element available. Redundant PM645 microprocessors are used for hot standby take over control.

6.3.2 Communication Boards AF100 redundant CI630 communication board and cable are used for hot Standby take over communication.


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6.3.3 I/O Boards For I/O boards types and quantity please see GT documentation.

6.4 Advant Controller 110 “AC110” Voltage Controller

AC110 computer keeps the application software for the generator voltage controller. It includes the following main parts:

1) Basic Station, comprising CPU and rack with back plane bus. 2) Communication Boards. 3) I/O Boards.

6.4.1 Basic Station.

The basic station is an AC110 equipped with the latest PC-element available. It has a single microprocessor type PM633.

6.4.2 Communication Boards.

AF100 communication board CI626 operates with two redundant bus cables. In case of disrupted bus cable the communication will switch to the intact bus.

6.4.3 I/O Boards.

For I/O boards type and quantity please see GT documentation.

6.5 Advant Station OS520

OS520 computer is a Hewlett Packard operator station wit UNIX operative system. The system consists of a workstation with 128 Mbytes RAM, 4 Gbytes hard disk, operator keyboard, mouse and colour graphic monitor 21”. The operator station has TCP/IP connection which is not used as standard. Also, it has software for the following:

• Displays for GT13 with its auxiliary system, HRSG13 and ST10. The displays

can be used to operate equipment in the same way equipment can be operated from CCR.

• Displays for logged signals. For each AC450 controller a limited value of tag no can be selected for regular sampling and storing for a short time to be used in a short time trend curve.

• Standard/object displays for each tag are available. • Effective dialogue for manual control of the turbo generator unit. • Process alarm and event list presentation.


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• DCS alarm list. The system is self diagnostic and all disturbances are shown on a special display page called system alarm page.

• Presentation of control system status. • Presentation of trend curves. Presentation of tags which are sampled in a log

table. When the station is used as an Engineering Station there are two main functions:

1) Configuration of operator displays. All operator displays are configured with the display configuration tool. Configured displays can be dumped to the DAT recorder to load the other 7 operator stations in the plant. Displays stored on DAT tape can be loaded from DAT recorder.

2) Configuration of AC450 application program. Modification of the application program for all AC450 can be carried out with the online Builder tool.

The following equipment will be present in the GT local control compartment: - Alarm/event printer. - Hardcopy printer. - DAT tape recorder.


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Equipment for GT11 is identical as for GT13 except for operator displays. Operator displays are included for GT11 with its auxiliary system and HRSG11.


Equipment for GT22 is identical as for GT13 except for operator displays. Operator displays are included for GT22 with its auxiliary system and HRSG22.


Equipment for GT24 is identical as for GT13 except for operator displays. Operator displays are included for GT24 with its auxiliary system, HRSG24 and ST20.


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10 GENERATING UNIT ST10

For detailed information about the ST equipment, please see ST documentation. All equipment are powered from 230VAC UPS and located in ST local control compartment.

10.1 AC160 Protection

AC160 computer keeps the application software for channel one of the protection systems. It has the following main parts:


10.1.1 Basic unit:

The basic unit is an AC160 equipped with the latest PC-elements available. Redundant PM645 microprocessors are used for hot standby take over control.

10.1.2 Communication boards:

For AF100 redundant communication board CI630 and cable are used for hot standby take over communication.

10.1.3 I/O boards:

For I/O boards types and quantity refer to ST documentation.

10.2 AC160 Turbine Controller

AC160 computer keeps the application software for turbine controller and channel two of the protection system. It has the following main parts:



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10.2.1 Basic station:

The basic unit is an AC160 equipped with the latest functions library available. Redundant microprocessors MP645s are used for hot standby take over control.

10.2.2 104BUCommunication boards:

For AF100 redundant communication board CI630 and cable are used for hot standby take over communication.

10.2.3 105BUI/O boards:

For I/O boards types and quantity refer to ST documentation.

10.3 46BDistributed I/O rack “S100 I/O “

The S100 I/O is a distributed I/O rack for the AC450 placed in the equipment control room. All steam turbine process signals are connected to this S100 I/O except protection and turbine controller signals. For I/O boards types and quantity refer to ST documentation. There is no monitoring equipment for local operation in the ST local electrical Compartment.


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11 Generating Unit ST20

All equipments for ST20 are identical as for ST10.


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12 Local Controller in Package Systems

All signal exchange to Programmable Logic Controller “PLC “are hardwired and designed to handle the most important functions. If something gets faulty in the PLC the operator has to go to the local control panel for further troubleshooting. The following are the existing local controllers “PLC’s “:

- One Siemens Simatic S5 95u PLC controls the fuel oil separator equipment,

the local control panel has mimic display and control buttons. - Four Mitsubishi Mel sec PLC controls the water treatment equipment. Each

line of the seawater reverse osmosis has a PLC, a mimic display and control buttons.

- The three lines for freshwater reverse osmosis and demineralization has one

common PLC, a mimic display and control buttons. - One Smart air PLC controls the air compressors, which supplies instrument

and service air. It has local control buttons.

- One Siemens Simatic PLC controls the condenser tube cleaning equipment. - Two PLC controls the diesel generators. - One PLC controls the hypo clorite unit for raw water.


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13 Clock synchronization

Events are continuously monitored and time tagged with the relative time accuracy of < 4 ms for the two Block 1 and Block 2 controllers AC450, which are externally clock synchronized. Whereas the relative time accuracy of events within the separate controllers < 5 ms when the MB300 control network is used for the clock synchronization. Events has the internal time accuracy of < 2 ms within one controller. The hardwired trips of the different units are monitored and time tagged in order that it should be possible to see the first out information during shut downs.


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14 DCS Operation

This section provides a basic understanding of the most important features and functions of the DCS that will be encountered during operation of the plant. The Operator Station keyboard is a regular computer type keyboard and mouse.

14.1 CRT Display

The CRT displays at Operator Work Station provide the information required to operate the plant equipment through the keyboard and mouse. At any one time, one of the CRT's is "active" meaning that any control actions performed by the Operator takes place on that CRT. The active CRT can be easy toggled using the keyboard or mouse. In general the plant systems are divided into separate "screens" which are displayed on the CRT. The screens resemble simplified P&IDs or diaphragm to help provide a graphic representation of the system and equipment. Additional information such as operating status and parameters are also displayed.

14.2 Process Graphics

The process graphics are comprised of piping and instrument diagram symbols or electrical single line diagram symbols. The graphics are dynamic to provide indication of equipment and process status. The indication of dynamic information will utilize both color changes and text to assure that this information can be discerned by all operators. All control loops (analog and digital) and any manually operated equipment with status or position indication are shown. Essential static components, such as process piping, are shown on the graphics.

14.3 Driven Equipment

For driven equipment, a solid shape representing the equipment type is used on the process graphic. Indication of equipment status, including alarm conditions, is provided by the use of different colors to fill the equipment symbol and abbreviated text descriptions of the status. For equipment with "Standby" or "Auto" modes of operation, a corresponding abbreviation is displayed to indicate the selected mode. When a piece of equipment has been tagged out, the corresponding abbreviation is displayed in the mode location. For pieces of equipment that have started permissive interlocks, the equipment label color is used to indicate if the permissive interlocks are satisfied. When all of the permissive interlocks are satisfied, the equipment label is displayed. If the permissive are not satisfied, the equipment label is displayed in another color.


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14.4 Vessels

Vessels, such as tanks and heaters, are depicted by an outline shape in the same color as static components. If an analog signal is provided for continuous level indication of a vessel, the vessel symbol or shape is filled proportional to the level signal. The remaining area in the vessel symbol is displayed in the default background color. In addition to the analog display of the vessel level, a digital readout of the level is provided adjacent to the symbol. The digital display includes the appropriate engineering unit abbreviation or symbol. For vessels that have level alarms provided in logic, the alarm indication is provided by changing the fill color and displaying a text indication of the alarm in or adjacent to the symbol.

14.5 Alarm Management System

The process alarm list has three priority level in different color: Red : Alarms related to trip signals. Yellow: Alarms related to start blocking of GT Purple: Other alarms.

14.6 Color of display symbols

Display symbols, which are used in the process displays, are presented with different colors dependent on the actual status of the corresponding process object. The following colors are used for different status:

Signal Color Description Green Normal status.

Red flashing

Unacknowledged alarm status in process displays and in ALARM list to indicate ”SHUTDOWN” alarms.

Red Acknowledged alarm with remaining alarm status in process displays. Also used for acknowledged ”SHUTDOWN” alarms in the EVENT and ALARM list.

Yellow

Blocked status. The object has been blocked by the operator or by the control system. Also used for acknowledged alarm presentation with START-INTERLOCK in the EVENT and ALARM list.

White Used to indicate that an object is selected by the operator. Also used as receipt of operator input at the operator input field

Purple Used for acknowledged ”ALARM” presentation in the EVENT and ALARM list.


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14.7 Digital Display of Process Values

In addition to motor amps, modulating valve positions and vessel levels, necessary process parameters and measurements are digitally displayed on the process graphics. The process values are displayed horizontally and, wherever possible, these values are placed adjacent to the associated symbol. If the graphic is too congested to locate the value adjacent to the symbol, a dashed leader line is used between the displayed value and the piping or equipment symbol. The dashed leader line is used when differential pressure measurements are displayed. Where multiple transmitters are used to measure the same process variable, the selected signal is used. The engineering unit abbreviations or symbols are included in the display of all process values.

14.8 Electrical Power Distribution Equipment

The circuit breakers, contactors, transformers, bus work and generators shown on the electrical power distribution graphics are represented by single line diagram type symbols. The indication of status (energized/not energized) is provided by the use of different colors for the line work and textual displays. Indication of breaker or contactor status is provided by the associated symbol being shown in the appropriate color and the appropriate status abbreviation being shown adjacent to the symbol. In addition to the contactor status, the motor current for the associated piece of driven equipment is displayed. For transformer, generators and bus work, indication of status is indicated by the color of the symbol and a digital display of the voltage and current associated with the equipment. The symbol color is determined from the analog signal associated with the voltage measurement for that piece of equipment.

14.9 Faceplate Graphics

The faceplate graphics provide detailed information that is used by the operator to interface with gas turbine that is controlled through the DCS. The faceplate graphics are comprised of up to eighteen or more control faceplates that are functionally associated and arranged in a logical order based on operating sequence. The faceplate graphics are accessed when an operator selects a process loop for control from a process graphic screen. In addition to control faceplates, the faceplate graphics may include process indicators and trends to provide all information necessary for the operator to successfully control the associated loop.

14.10 Trend Displays

Trend displays are included in the faceplate graphics as required for a comprehensive view of the loop controlled from that graphic. The trend area has up to eight different points displayed at once and is outlined in color. The time


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span for the trends can be varied by minutes, hours, or days. The trend area location is fixed in the middle of the graphic screen. There are four rectangular areas on the right hand side of the trend area that is used to describe the points being trended. The description will consist of the name of the trended process value, a digital display of the process value with engineering units and the upper and lower process value boundaries for the trended point. The text for the point description and the associated trend line is shown in the same color. Each point that a trend is provided for has a unique color so that the trend lines can be easily distinguished. The colors used are assigned generically to points 1 through 8, with point 1 at the top and point 8 at the bottom.

14.11 Operator Interface and Control

Access to functions available from a process graphic (selection of equipment or loop for control, selection of related process graphics, selection of point detail information and selection of associated window graphics) is accomplished by positioning the cursor in areas defined as a "Poke Field". Each "Poke Field" is assigned a specific function and is as large an area as practical. Positioning of the cursor in the "Poke Field" is accomplished by use of the Operator Work Station keyboard or Operator Work Station mouse. The "Poke Field", with the exception of analog point displays, is distinguished by a box encompassing the area. The box color will flash when the "Poke Field" is accessed. The analog point displays are automatically assigned "Poke Fields" by the DCS operating software. Since this is an automatic feature with no exceptions, it is not necessary to distinguish these "Poke Fields". All equipment selections on a graphic can be cleared by accessing a "Poke Field" located in the upper right hand corner of the graphic.

14.12 Digital Control

When a piece of equipment with on/off type controls is selected, the box color indicating the "Poke Field" will flash to alert the operator that the control keys on the Operator Work Station keyboard are active for that piece of equipment. When a piece of equipment is selected to start, the permissive display (where applicable) is provided at a pre-selected location on the screen and the control logic will verify that all start permissive interlocks are satisfied. If all start permissive interlocks are satisfied or if there are no start permissive, the "Start/Stop" key on the Operator Work Station pop-up is enabled for that piece of equipment. If there are start permissive interlocks that are not satisfied, the control logic will not allow operation of the equipment and will go to the permissive pop-up.


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The operator can call up the equipment permissive display or detail display by selecting the piece of equipment. Equipment detail displays are accessed via dedicated "Poke Fields".

14.13 Operator station password

All the operator stations will have passwords for three levels of station handling permits.

- Supervisor: permits to select displays and alarm/events lists. No permission to acknowledge alarms, operate objects.

- Operator : Permit to acknowledge alarms, operate objects, no

permission for configuration of system.

- Engineer : Permit of configuration of system.


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15 Single Failure Criteria

A single failure in following parts of DCS system will not cause shutdown of any generating unit.

15.1 Operator Stations in CCR

There are four operator stations in CCR. If one of them failure there is still three with full operation facilities for all components in plant.

15.2 Operator Stations in GT LCR

The GT is normally not operated from LCR. All GT operator mimics are included in CCR operator stations.

15.3 Control network MB300

The control network is based on a redundant Master Bus300 .two redundant fibers cables perform it. From a functional viewpoint, the redundant networks work in a hot stand by implementation. This means that the primary network has the communication responsibility. The secondary network stands by automatically take over incase of fault in the primary network. This take over is made bumbles without any manual action.

15.4 Control network Star Coupler

The Star coupler connecting the fibers in the control network is divided into two parts for each network. It is supplied with redundant power supplies.

15.5 Advant Controller AC450 processor and memory

Redundant microprocessor is used is a backup to normal are selected microprocessor. At indicated fault in the pre selected microprocessor, the redundant microprocessor will take over control. This take over is made bumbles without any manual action CPU and memory board type: PM511V08.

15.6 Advant Controller AC450 Communication card for MB300

Redundant communication board and cable are used. From a functional point of view, the redundant networks work in a hot stand by implementation. This means that the primary network has the


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communication responsibility. The secondary network stands by automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action. Communication board type CS513.

15.7 Advant Controller AC450 Communication card for AF100

Redundant communication board and cable are used. From a functional point of view, the redundant local control networks work in a hot stand by implementation. This means that the primary network has the communication responsibility. The secondary network stands by automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action. Communication board type CI522.

15.8 Advant Controller AC450 power supplies

Block AC450 are supplied with double incoming 230VAC UPS power supplies, redundant power supplies transformers 230 VAC-24VDC and redundant voltage regulators 24VDC-5VDC. GT AC450s are supplied with single incoming 230VAC UPS power supplies; some of the parts in the internal power supply are redundant.

15.9 Field networks AF100

The field network is based on redundant AF100.Two redundant fiber /twisted-pair/coax cables perform it. From a functional point of view, the redundant networks work in a hot stand by implementation. This means that the primary network has the communication responsibility. The secondary network stands by automatically take over in case of fault in the primary network. This take over is made bumbles without any manual action.

15.10 Advant Controller AC160 Processor

Redundant microprocessor and memory are used for hot standby take over control.

15.11 Advant Controller AC160 Processor Communication card for AF100

Redundant communication board and cable are used for hot standby take over communication.


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15.12 Advant Controller AC160 power supplies

Some of the parts in the power supply are redundant.

15.13 Distributed S800 I/O stations communication card for AF100:

Redundant communication board and cable are used for hot standby take over communication.

15.14 Distributed S800 I/O stations power supplies:

Distributed S800 I/O stations are supplied with double incoming 230VAC UPS power supplies transformers 230VAC –24VDC. A fault on an individual I/O card can cause to shutdown of generating unit, for example analogue controller outputs.


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16 SELF- DIAGNOSTIC

The control system equipment of the Advant family OCS is built up of different components and each of them has relevant self-diagnostic built in. For each component the user manual have information concerning the self-diagnostic and most of the components have announcements for faults on the diagnostic displays on the operator stations.


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17 PROCESSOR AND BUS LOAD, SPARE CAPACITY

Cycle times of application programs is set in relation to the specific requirements. The controllers are sized for the expected load of the application. The screen response time to operator shall not exceed 2 seconds. The design is based on 20% wired spare capacity.


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18 SYSTEM OPERATION

18.1 Normal Operation Valve Alignment List

Refer to SOP for each system to see the valve list.

Valve Number Description Position N/A

18.2 Normal Operation Power Supply List

The equipment allocated for block one will be powered from block 1 230 VAC UPS, equipment allocated for block 2 will be powered from block 2 230VAC UPS.

Description Power

Source Location Position/Status

Block 10 230 VAC UPS

Block 10 Battery Room (10BRU10*) CLOSED/ON

Block 20 230 VAC UPS

Block 20 Battery Room (20BRU10*) CLOSED/ON

GT11/13/22/24 230 VAC UPS LCR (*BPA10) CLOSED/ON

ST10/20 110 V DC rectifier

ST Switch Gear (*BUA12) CLOSED/ON

Protection Sys. Block10

110 V DC rectifier

Block 10 Battery Room (10BUB10) CLOSED/ON

Protection Sys. Block20

110 V DC rectifier

Block 20 Battery Room (20BUB10) CLOSED/ON

18.3 System Prerequisites

1. The Electrical Distribution System is in service. 2. All clearances have been released.


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18.4 System Startup

Step No.

Description

Initials/ Remarks

NOTE:

The DCS systems operates 24-hours a day and does not shut down as the plant cycles on and off. This procedure is typically followed after a major shutdown, outage, or after maintenance has been performed on the DCS

18.4.1 VERIFY power supply is available for DCS control

consoles to be started.

18.4.2 TURN ON control stations as required.

18.4.3 VERIFY control station perform self-diagnostics.

NOTE After self-diagnostic test, the DCS can be operated as

described in the description section of this SOP.

18.4.4 OPERATE plant as directed by SOP’s.

NOTE: Once the DCS has been properly setup, adjustments

should not be required. The system is designed to react with plant load changes. The primary responsibility of the Operator is to note any changes and react to alarm/trip conditions

18.5 System Normal Operation

The following checks should be made periodically to ensure the system and equipments are operating correctly:

1. Periodically verify system is operating properly. 2. Verify alarms are printing to printer. 3. Verify any un-cleared alarms are responded to by the operations team.


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18.6 System Shutdown

Step No.

Description

Initials/ Remarks

NOTE:

The DCS system operates 24-hours a day and does not shut down as the plant cycles on and off. This procedure is typically used when preparing for a major shutdown, outage, or a maintenance task on the DCS system.

3.6.1 VERIFY DCS is no longer needed for operation.

3.6.2 VERIFY all plant systems are shutdown and operation

will not be changed for an extended period.

3.6.3 Locally SHUTDOWN control consoles as required


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19 INSTRUMENTATION/ALARMS 19.1 I&C Matrix

Refer to the individual system SOPs to determine the parameters for an individual system.

Instrument

No. Description Normal Value DCS Address

N/A

19.2 Fault Procedures Refer to the individual system SOPs to identify fault procedures associated with an individual system.

Alarm/Condition

Possible Cause

Action

N/A


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20 SYSTEM HISTORY


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21 SYSTEM MODIFICATIONS

1. DSS: the Two PI API nodes PC operating systems were upgraded from Windows NT to windows XP, whereas the PI server workstation was upgraded from Windows NT to Windows 2000 Server.


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22 SYSTEM UNTREATED MALFUNCTIONS

1. Compressed Air : Smart Air PLC is still has an alarm, DCS fault signal is (00QEA10EG001XR02) and appearing in Disp.20


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23 SYSTEM LAYOUT


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24 HAZOP Methodology

The Hazard and Operability (HAZOP) technique was used to address hazards of the process, previous incidents, which had a likely potential for severe consequences in the work place, engineering and administrative controls and consequences of failures of those controls. Additionally, facilities sitting, human factors, and a qualitative evaluation of a range of possible safety and health effects were made.

24.1 Risk Matrix

Consequence

Frequency Range Qualitative Criteria

4 (>1/100yr.)

Single instrument or valve failure; hose leaks; or a human error in everyday activity.

3 (1/100-1/1000 yr.)

Dual instrument or valve failures; hose ruptures; or piping leaks; or human errors.

2 (1/1000-1/10000

yr.)

Combination of instrument failures and human errors; or full-bore failures of small process lines or fittings.

1 (1/10000 yr.)

Multiple instrument or valve failures or human errors; or spontaneous failures of tanks or process vessels.

4 C B A

A 3 C B B

A

2 D C B B

1 D D C C

1 2 3 4

Frequency


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Consequence Range

Qualitative Criteria

4 Personnel- Potential for multiple life-threatening injuries or fatalities. Public- Potential for multiple life-threatening injuries or fatalities. Env.- Unconfined release with potential for major environmental impact. Eqpt.- Plant damage/loss value in excess of U.S.$ 100 million.

3 Personnel- Potential for life-threatening injuries or single fatality. Public- Potential for life-threatening injuries or single fatalities. Unconfined release with potential for medium environmental impact. Eqpt.- Plant damage/loss value in the range of U.S.$ 10-100 million

2 Personnel- Potential for severe injury requiring physician’s care. Public- Potential for severe injuries requiring physician’s care. Env.- Unconfined release with potential for minor environmental impact. Eqpt.- Plant damage/loss value in the range of U.S.$ 1-10 million.

1 Personnel- Potential for injury requiring first aid. Public- odor or noise nuisance to the public. Env.- Contained release with localized impact. Eqpt.- Plant damage/loss value in the range of U.S.$ 100,000-1 million.


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24.2 HAZOP matrix

Item No.

Deviation

Cause Consequence Engineering and Administration

Controls

L C R Recommendations

15.05 No/low flow

GKB-44-AA001 fails closed

fail RO, overheat pump and damage

PS-GBK44-CP005 stop pump(s) alarm in DCS

2 2 C 15.05.1: Investigate installing recirc line on pump GKB42AP001

20.09 Loss of containment

Break of pump motor casing

Short out and burn the motor coils

UZA GAA42 CU005 shuts off current, alarm to DCS Protective coating on casing cathodic protection on pump

1 1 D 20.09.1: Team decided no recommendation required

26.03 No/low flow

LISA MAG10 CL015 indicates false low level

lose dearator level, makeup valve go wide open, GK10AA20, hot well level rises, trip out turbine, water back into turbine and turbine damage

2 our of three voting trip turbine LIA10 MAG10CL005 indicator to check against Operator can operate in manual from DCS Field LI

1 2 D 26.03: Team decided no recommendation required

No/low flow

GCK10AA120 fails closed

lose dearator level, trip unit

Alarms on valve position in DCS to alert bypass around valve capacity of condensate return system

1 1 D 30.05.1: Team decided no recommendation required

Where; L= Frequency Range C= Consequence Range R= Risk range Item No. = indicates the number mentioned in the main HAZOP matrix.


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25 REFERENCES

This manual should be used in conjunction with the vendor-supplied manuals for the equipment and/or systems. This manual is meant to supplement but never replace or supercede vendor data. 1. The available ABB system description. 2. Main HAZOP Matrix

GAZA POWER GENERATION COMPANY 140MW CCGT POWER … SOP-012-DCS(R5).pdf · System Startup ... Plant...

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