Turbomach Turbotronic 4 Controls System Brochure - Rev J

5/19/2018 Turbomach Turbotronic 4 Controls System Brochure - Rev J

2009 Solar Turbines Incorporated. All rights reserved. Rev_J May 2013

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Turbotronic4 Control System

Turbomach SAvia Campagna 15

CH-6595 Riazzino Switzerland

Caterpillar is a trademark of Caterpillar Inc. Solar, and Turbotronicare trademarks of Solar Turbines Incorporated. Allother trademarks, service marks, or registered trademarks appearing in this specification are the intellectual property oftheir respective companies. Specifications are subject to change without notice.

Direct customers who receive this Turbomachinery Package Specification along with the purchase of their originalequipment may make limited copies of parts of this specification for use in the creation of their own specificationdocuments. However, such customers shall not distribute any part of this Turbomachinery Package Specification outsidetheir own organizations for any other purpose. Any other use without permission is strictly prohibited.


Turbotronic 4 Control System


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Table of Contents

1

OVERVIEW...........................................................................................................................3

2 CONTROL SYSTEM CONFIGURATIONS ..................... ........................ ....................... ........4

2.1

Advantages of Onskid Controls ......................................................................................................5

2.2

Advantages of Offskid Controls ......................................................................................................5

2.3

Operator Interface...........................................................................................................................5

3 SYSTEM DESCRIPTION ..................... ......................... .......................... ...................... ........6

3.1

CONTROL PROCESSOR ..............................................................................................................6

3.2

PROCESSOR SOFTWARE............................................................................................................6

3.3

UNIT CONTROL NETWORK..........................................................................................................8

3.4

INPUT/OUTPUT (I/O) MODULES ..................................................................................................8

3.5

BACKUP SHUTDOWN SYSTEM .................................................................................................10

3.6

VIBRATION MONITORING SYSTEM...........................................................................................10

3.7 FIRE MONITOR............................................................................................................................113.8

GAS MONITOR ............................................................................................................................11

3.9

COMBINATION GENERATOR CONTROL MODULE ..................................................................12

3.10

POWER SUPPLIES......................................................................................................................12

4 TT4000 DISPLAY AND MONITORING SYSTEM ...................... ......................... .................13

4.1

VIDEO DISPLAY UNIT .................................................................................................................13

4.2

TT4000 REMOTE.........................................................................................................................29

5 TURBINE CONTROL..........................................................................................................30

5.1

SEQUENCING..............................................................................................................................30

5.2

CONTROL ....................................................................................................................................31

5.3

PROTECTION..............................................................................................................................32

5.4

DISPLAY.......................................................................................................................................32

6

GENERATOR CONTROL...................................................................................................33

6.1 EXCITATION CONTROL MODES................................................................................................336.2

SYNCHRONIZATION...................................................................................................................34

6.3

LOAD SHARING...........................................................................................................................34

6.4

PROTECTION..............................................................................................................................35

6.5

KILOWATT CONTROL.................................................................................................................36

7 SUPERVISORY COMMUNICATIONS.................................................................................37

7.1

DATA INTERFACE.......................................................................................................................37

7.2 COMMUNICATION PROTOCOLS ...............................................................................................37

8 OTHER FEATURES AND OPTIONS .................... ......................... ...................... ...............38

8.1

SOFTWARE MODIFICATION ......................................................................................................38

8.2

LANGUAGES FOR TT4000 DISPLAY .........................................................................................38

8.3 ENGINEERING UNITS.................................................................................................................39

8.4

PRINTERS....................................................................................................................................39




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1 Overview

The Turbotronic 4 control system provides precise integrated control, protection andmonitoring of Turbomachs turbomachinery packages. It brings Solar and Turbomachsoperating experience to current controls technology, providing rugged and reliablesystems with broad functionality. The backbone of each unit control system is aControlNet network that connects the key components and subsystems listed below, ashighlighted in Figure 1:

Control Processor. The Allen-Bradley ControlLogix processor is the primary controldevice in the system.

I/O Modules. The Allen-Bradley Flex input/output (I/O) modules provide the interface

between the package instrumentation and the processor.

Vibration Monitoring. The XM Dynamic Measurement monitorsvibration for the turbine

and driven equipment.

Generator Control. The Allen-Bradley / Basler Electric combination generator controlmodule (CGCM) provides multiple power generation control and protection features,including synchronization and voltage regulation.

Backup Protection. A separate backup shutdown system shuts the package down in asafe and orderly manner if primary control is lost.

Operator Interface. TT4000 Display and Monitoring System, fully functioned HumanMachine Interface (HMI) product, one on-skid mounted, one auxiliary desktop PC.

Fire Monitoring. A separate certified fire monitoring system provides fire detection andfire extinguishing.

Section 3 provides a more detailed description of these components and subsystems.

Figure 1. Turbotronic 4 Architecture




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2 Control System Configurations

The control system components are mounted on panels and cubicles located on anacclimatized room. This control room is mounted on-board of the main skid (on-boardcontrol room). This configuration is typically called on-skid Control. For some turbinemodels theres the possibility to have a remote control room and in this case theconfiguration is typically called off-skid Control.

Turbine Model On-skidOption

Off-skidOption

Mercury 50 Yes No

Mars 100 Yes No

Taurus 70 HED Yes No

Centaur 40 Yes Yes

Centaur 50 Yes YesTaurus 60 Yes Yes

Package without on-skid Control Room (example)

Package with on-skid Control Room (example)

Thanks to the modularity of the new control room, its now possible to install theturbogenerator also in areas where the space is reduced giving the chance to thecustomer to place the control room somewhere else.




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2.1 Advantages of Onskid Controls

Reduced Cabling. The major advantage of the onskid control system is the largereduction in interconnect cabling. Having the control, the auxiliary, the starting and thesupply panels in the same control room placed on skid, connections are minimal. Mainpower supply and a few signals from/to customer panels are required, while all wiresneeded, from and to the package, cover a short path. This greatly reduces the bulk andcost of the cables.

Factory Wiring.The package, including the control system, is wired and tested at thefactory. These connections stay in place and do not have to be rewired in the field. Thisreduces commissioning time and the opportunity for wiring errors.

Figure 2. Standard Configurations for Onskid Controls

2.2 Advantages of Offskid Controls

Reduced Space. The major advantage of the offskid control system is the spacereduction required to install the package that now can fit also in small places. All I/Osignals are collected in a small auxiliary panel and data are transmitted to the maincontroller through ControlNet network. Power supply cables and ControlNet cables arethe only ones that have to be laid, while all other wires, from and to the package, cover,also with this option, a short path. This greatly reduces the bulk and cost of the cables.

Factory Wiring.The package is wired and tested at the factory. These connections stayin place and do not have to be rewired in the field. This reduces commissioning time andthe opportunity for wiring errors.

2.3 Operator Interface

The operator interface consists of a TT4000 display system with keyboard and track-ballmouse that is typically used during commissioning and servicing.

Expanded operator interface is available offskid, typically in a control room area, with adesktop computer configured with the TT4000 system.

AUXILIARY DESKTOPCOMPUTER

CONTROLNET

ETHERNET

PACKAGE SKID

ON-BOARD CONTROL ROOM

CONTROL PROCESSORI/O MODULESBACKUP SHUTDOWN SYSTEMFIRE & GAS SYSTEMVIBRATION MONITORGENERATOR CONTROL MODULE

TT4000




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3 System Description

3.1 CONTROL PROCESSORThe ControlLogixcontrolprocessor (Figure 3) provides primary package and gas turbinecontrol. It governs the gas turbine, the fuel supply, and the functioning sequences ofturbogenerator as well as all associated equipments, according to the different systemsrequirements.

The ControlLogix processors, manufactured by Allen-Bradley, are part of a scalablefamily of "Logix" processors representing the state-of-the-art for industrial processcontrol. The devices offer several important advances:

They mount in an Allen-Bradley 1756 style rack, which has an integral power supply andcan accommodate various communications interface modules, such as ControlNet,Ethernet, Data Highway Plus and Modbus.

The symbolic software architecture is "tag-based," which means program variables arenot tied to physical memory addresses in the processor, but are identified by symbols.The symbols reside in the processor. This tag-based architecture is an extremely powerfulfeature that enables rapid duplication of predefined program subroutines and permitsportability within the Logix family of processors.

Figure 3. ControlLogix Processor

Another key benefit of the Logix processors is the ability for field service to makemaintenance updates easily, since each subroutine is self-contained and does not affectother sections of the program. The ControlLogix processor, together with RSLogix 5000programming software, provides a solid and flexible platform for Turbotronic 4 controlsystems.

3.2 PROCESSOR SOFTWARE

The RSLogix 5000 software programming environment offers a Windows-based interface(Figure 4) that supports symbolic programming with structures and arrays. Thisenvironment is common to the Rockwell Automation Logix family of processors(ControlLogix, FlexLogix, and MicroLogix) and sets the foundation for future growthtoward distributed control systems.

The new programming environment enables the development of predefined and qualifiedsub-system software modules. Each software module is a self-described building block.Each building block supports a corresponding control system feature.

The result is flexible and robust software with consistent quality. The RSLogix 5000structure yields a measurable increase in product quality and shortens commissioning




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cycles. It permits more flexibility in accommodating special balance of plant controlsrequirements without affecting the predefined software modules used for the control ofthe turbomachinery.

Figure 4. RSLogix Software

RSLogix 5000 is compliant with the IEC 61131-3 software-programming standard. Itoffers multiple industry standard programming languages, which can be selected to suitthe application:

Ladder program for relay-type sequential logic

Function blocks for logical processes and mathematical functions

Structured text allows the creation of user-defined functions for further optimization of thecode for turbine control applications.

In total, RSLogix 5000 provides the flexibility to build more compact and better-organizedcode that is efficient to operate and easier to troubleshoot.




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3.3 UNIT CONTROL NETWORK

The control processor communicates with the other components of the system using

ControlNet 1.5. This high-speed network operates at five megabits per second. It isdeterministic and repeatable, meaning that data and instructions adhere to a rigidschedule during each network update. A typical network update time for the controlsystem is five to ten milliseconds. The physical connection is by redundant cables; that is,two duplicate channels connect all devices on the network (Figure 5).

Figure 5. Network Adapter

3.4 INPUT/OUTPUT (I/O) MODULES

To perform many of its functions, the control processor must gather physical data fromand send control commands to the package instrumentation. This is accomplishedthrough input/output (I/O) modules. These are supplied as discrete (input, output, orboth) or analog (input, output, or both) modules. Discrete inputs are typically used foralarms, shutdowns, and status indications. Analog inputs are used for scalable functions.

The I/O modules are mounted to terminal bases (Figure 6). Terminal bases have twoprimary functions. First, when connected side to side, they serve as a back plane,allowing data to be transferred from the I/O module to a network adapter module andthen to the processor via ControlNet. Second, the terminal base acts as the terminal stripfor wiring from the field devices. The network adapter serves as a communication hubbetween each of the attached I/O modules and the processor, providing not only I/O databut also individual module and health status. In addition, the adapter provides the DCpower for the I/O modules. Up to eight I/O modules may be connected to one networkadapter.

Discrete Input Modules. Discrete input modules receive signals from on/off devices,

such as level switches, pressure switches, push buttons, relays, and protectiveequipment normally used during sequencing of the gas turbine. Discrete signals can beused for alarms, shutdowns or simply indicators, but are not necessarily displayed. Thediscrete input modules have a capacity of up to 16 channels, depending on theconfiguration.




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Figure 6. Flex I/O Module and Terminal Base

Network Adapter. The adapter module interfaces the FlexIO modules to an I/O scannerport across a communication network. The adapter module contains a built-in powersupply that converts 24V dc to 5V dc for the backplane to power the FlexIO modules.

One adapter communicates with up to 8 I/O modules

Terminal base.Each FlexIO module requires a terminal base unit that snaps onto theDIN rail to the right of the communication adapter. The terminal bases provide terminalconnection points for I/O wiring.

Discrete Output Modules. Discrete output modules drive output devices such assolenoid valves, relays and motor contactors. The modules are available in both 8 and 16channel versions.

If "dry" contacts are required, then a set of interposing relays are provided.

Analog Input Modules. Analog input modules accept analog signals and digitize thedata for transfer to the processor. Modules can accept either four or eight single-endedinputs, with different channels being used for different types of inputs. Each channel isindividually configured for current or voltage by choosing where the input is connected onthe terminal base.

Analog Output Modules. Analog output modules send analog signals to position controldevices, such as valves, or to provide information for display. The standard analog outputmodule has four channels.

Temperature Modules. Temperature modules condition and transfer temperature datafrom package resistance temperature detectors (RTD) and thermocouples to theprocessor. 100-ohm platinum RTDs are preferred. The temperature module has eightinput channels.

Speed Modules. Speed modules perform high-speed frequency algorithms. Thefrequency inputs can be up to 32,767 Hz. The speed module has two input channels,each of which can accept magnetic pickup signals from 500 mV to 28 VAC peak.




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3.5 BACKUP SHUTDOWN SYSTEM

The basic control system is equipped with an independent backup system that initiates

emergency shutdown of the turbomachinery and controls the post-lube cycle if theprimary processor fails. Critical input signals monitored independently by the backupsystem include the backup power turbine overspeed monitor, manual emergency stopswitches (located at the turbine skid), the processor fail "watchdog," and the fire systemrelay contacts. When activated by any of the above faults, the relay backup systeminitiates a safe shutdown of the turbine. The backup control system is a combination ofinstantaneous and time delay relays.

When a failure of the processor occurs, all discrete outputs are automatically switchedoff. The microprocessor fail relay is de-energized on a fault condition. A fault is initiatedby a "watchdog" circuit that monitors the PLC healthy status. The microprocessor failrelay contacts in the relay backup system initiate an emergency shutdown and isolate thegenerator by commanding the circuit breaker to open.

Once a shutdown is initiated by the backup system, operation can only be restoredmanually by a safety lockout push button on the onskid control room, after all faults havebeen cleared. This action re-energizes the master control relay and restores associatedrelays and timers to the normal position.

3.6 VIBRATION MONITORING SYSTEM

Turbotronic 4 includes integrated vibration monitoring with the Allen-Bradley 1440 XMDynamic Measurement Vibration Monitor (Figure 7). The 1440 XM Vibration Monitorpermits physical distribution of the vibration monitoring system, as it integrates with theoverall control system using Flex I/O ControlNet network adapters. The 1440 XMVibration Monitor integrates seamlessly into the ControlNet 1.5 system architecture.

Figure 7. 1440 XM Dynamic Measurement Vibration Monitor

The 1440 XM Dynamic Measurement Module consists of the following components:

Terminal base

Power supply 24-Vdc

ControlNet adapter

Field monitor modules (proximity probes, accelerometer, velocity, ecc.)

Keyphasor (supplied when applicable)

Each 1440 XM field monitor modules can receive 2 vibration channels and akeyphasor input. Typically, four or more 1440 XM field monitor modules are used on apackage, depending on the number of vibration channels to be monitored.




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The vibration data processed by the 1440 XM Dynamic Measurement Module istransmitted to the ControlLogix processor through the ControlNet network for alarmingand shutdown. Vibration data values are viewable on the HMI.

3.7 FIRE MONITOR

A separate fire control system is provided. The Siemens Cerberus CS1140 monitorprovides fire protection and extinguishing agent release using optical flame detectors andsmoke detector (on-board control room).

This sensor information is then transmitted to the Cerberus control unit to execute the firesuppression logic, to control agent release, signaling, and annunciation outputs, and tocommunicate with the Turbotronic4 control processor to initiate turbine shutdown.

Figure 8. Fire Monitor

3.8 GAS MONITOR

The enclosure area is monitored for possible gas leakages by at least two infrared gassensors. One sensor is located at the outlet air flow of the enclosure. The second islocated in the area of the gas supply line.

The sensors provide an analogue signal that correspond to the Lower Explosive Level(LEL), and are wired to the main processor input modules. The main processor monitorsthe LEL and initiates a turbine shutdown when the maximum allowable level is exceeded.

Figure 9. Gas Sensor




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3.9 COMBINATION GENERATOR CONTROL MODULE

In Turbotronic 4 control systems for generator packages, the integrated combinationgenerator control module (CGCM) (Figure 10) provides extensive generator control andprotection functions. The functions of line synchronization and automatic voltageregulator are combined into a single device with additional control and protectioncapabilities. Refer to Section 6 for a more complete description.

Figure 10. Combination Generator Control Module

3.10 POWER SUPPLIES

The Turbotronic4 control system operates on 24-Vdc power. The package is equippedwith a 24-Vdc battery charger and battery system.Depending on the gas turbine package type, a 110-Vdc system may also be required to

power the engine actuators, the fuel valve actuators and/or the DC backup lube oil pump.These packages are also equipped with a 110-Vdc battery charger and battery system.

The I/O modules, the vibration monitor, the CGCM, the backup shutdown system, the firesystem and display systems operate with 24-Vdc power.




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4 TT4000 Display and Monitoring System

The TT4000 Display and Monitoring System is a Human Machine Interface (HMI) productdeveloped by Solar Turbines Incorporated and Turbomach SA specifically forturbomachinery control applications.

TT4000 displays and stores data and provides a range of control interface capabilities.TT4000 interfaces with, but is separate from, the package control system. This allowsTT4000 to perform multiple tasks without interfering with the critical control and protectionfunctions handled by the control processor.

TT4000 provides a window into the package control system. It shows engine conditions,stores information, alarms, shutdowns, and events, and can permit varying levels ofcontrol. While beneficial to an operator, the TT4000 is not essential for the control of thepackage, since that responsibility rests with the package control system.

TT4000 is a flexible and expandable product. With the following features, TT4000 is

consistent with current industry software standards: The system runs under the Windows XP operating system.

The system is compliant with Transmission Control Protocol and Internet Protocol (TCP /IP) to permit easy transmission of data between TT4000 and other programs.

Historical data are readily viewable within the program. Also, files in Comma SeparatedValue (.csv) format can be created for easy export to other programs such as MicrosoftExcel.

TT4000 incorporates Visual Basic for Application (VBA) scripting that can be used toassist in the analysis and reduction of data.

The program supports Active-X controls.

The TT4000 family of systems includes various configurations to support differentoperational requirements:

TT4000is a fully featured display and monitoring system consisting of a panel-mountedvideo display unit (VDU) configured with the Windows XP operating system, the TT4000application software and the specific project software files. The system can storeextensive amounts of data in addition to its display, communications and control functionscapabilities. It is designed for operation in a nonhazardous area such as a control room.

TT4000 Remoteis the version of TT4000 installed on a "remote" PC. It mirrors thefunctionality of the primary TT4000 system.

4.1 VIDEO DISPLAY UNIT

The video display unit (VDU) consists of an industrial computer and Human Machine

Interface (HMI) display software. The VDU with TT4000 HMI software performs severalkey functions to facilitate operation of the turbomachinery equipment through a user-friendly interface. The HMI system monitors the turbine and driven equipmentparameters, calculates performance factors, annunciates alarms, reports on the runningstatus of the equipment, stores data and provides a comprehensive set of analysis tools.

TT4000 can be integrated as part of a larger network for data sharing and remote displaycommunications.

The VDU operates independently of the control system and provides additional operatorand maintenance information. Typical screens include:




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4.1.1 Standard Display Screens

Overview:

Operation Summary

Process Summary

Engine Summary

Enclosure

Systems:

Operation sequence

Control System

Engine and Generator Vibration

Lube, Fuel and Starting Systems

Details:

Fuel, Engine, Lube and Temperatures Details

Advanced Vibrations Tools:

Maintenance

Alarm, Event and Historical Log

Constants

Strip Chart

4.1.2 Optional Display Screens

Gas Turbine Performance Map (Figure 34)

While any of the screens are being displayed, there is a full-time indication of fault

conditions. The top line of the display screen is dedicated to the identification of up to fouralarm conditions. If there are more than four, the operator is directed to go to the AlarmSummary screen for a complete sequential listing.

4.1.3 Overview

Operation Summary provides a view of the overall gas turbine and drivenequipment operating parameters (Figure 12).

Process Summary provides all the instruments to monitor, synchronize andcontrol the turbomachinery (Figure 13).

Engine Summaryprovides a list of engine parameters and gives the possibilityto control the engine (Figure 14).

Enclosure allows to monitor the ventilation, fire & gas conditions and other

parameters about the enclosure (Figure 15).

4.1.4 Systems

Operation Sequencescreen also displays the starting and stopping sequences.During the package start sequence, the VDU shows the various logics and timedsequences involved from initiation of start- up to running condition. Should theunit fail to start, the operation display screen indicates the particular stage in thestart logic sequence in which the start failed. This feature is a valuabletroubleshooting resource for operations personnel to quickly identify the sourceof the starting problem and, thus, reach a faster solution (Figure 16).

Control Systemscreen shows turbine and generator main parameters and theoperator has the possibility to open the control pages (Figure 17).




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Engine and Generator Vibration screens allow the operator to monitor indetailed the vibrations measured (Figure 18 & Figure 19).

Lube, Fuel and Start Systems screens show the main parameters of these

auxiliary systems in special graphic pages (Figure 20, Figure 21 & Figure 22).

4.1.5 Details

Fuel, Engine, Lube and Temperatures Detailsare a group of special screenswhere all the value, measured and calculated, of these subsystems are shown indetails. In this section, temperatures are also shown in graphic way using chartsand bargraphs (Figure 23, Figure 24, Figure 25 & Figure 26).

Advanced Vibrations is a screen composed by several subpages used for adepth vibrations analysis (Figure 27).

4.1.6 Tools

Maintenancescreen provides instruments for maintenance tests and operations(Figure 28).

Alarm, Event and Historical Logdisplay all alarm and shutdown annunciationswith a time and date stamp, monitors and records the changes in status of alldefined discrete (switch or binary) inputs (events) and allows selection of up to10 variables for viewing in a digital strip chart format (Historical).

Alarms (Figure 29) are time stamped by the HMI in the order in which they arereceived from the control processor. On the display, alarms are shown in yellowand shutdowns in red. Acknowledged alarms are shown in reverse video. As themalfunctions are acknowledged, they are shown in the corresponding coloredtext until they are cleared from the system and the RESET switch is pressed. Thefirst four malfunctions detected are displayed at the top of all screens untilcleared.

The events are displayed as a chronological, time-stamped listing in the order inwhich they occurred (Figure 30). It is possible to have multiple events with thesame time stamp due to the update rate of the display system. Up to 5000 eventscan be stored in the log. The order of the event listing on the screen can bechanged by double clicking on the column headings. This feature provides ahistorical record of sequence and status events that changed. It can be used toaudit package operation or to identify malfunctions that have occurred and areasof the operation that need attention.

The objective of historical data monitoring (Figure 31) is to provide information ofa type and in a format that allows informed decisions to be made in the areas of

operation, maintenance, and optimization of the turbomachinery and associatedequipment. The information is collected in databases for online viewing andanalysis. Alternatively, Comma Separated Value (.csv) format files can becreated for export to other software programs such as Microsoft Excel.

Historical data monitoring includes the groups listed below. To view them online,the user selects, from pull-down menus, the desired variable, the pen color, andpen style. Available historical groups include:

Hourly Log.Data are read at one-hour intervals for the past 12 months andstored, one database for each month. This log includes the "Elapsed Time"feature, which records data whether or not the equipment is running.

Minute Log.Data are read at one minute intervals for the past month andstored, one database for each day.




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10-Second Log.Data are read at 10-second intervals for the last 14 days,one file for each day. These files can only be analyzed off-line.

Trigger Log.The Trigger Log function stores data before and after a "trigger

event." The trigger event is defined and configured in the control processor.The standard event is a shutdown. Each time the event is triggered, a timerstarts. At the end of two minutes, all the analog data for the previous sixminutes are written to a file. In this way, data for four minutes before and twominutes after the event are captured. Up to 25 triggered files, eachcontaining six minutes of one-second data points, are stored. This is apowerful diagnostic tool.

Constants screen (Figure 32) displays a set of adjustable values in theprocessor software listed by address number. To change a value, a constant isselected by tag name or address number: double clicking the item brings up thelogging menu. Username and password are entered, bringing up the parameterwindow. The new value can then be entered. The parameter window displays theallowable range and resolution accuracy. Once the new value is entered, it is

transmitted to the control processor. TT4000 also creates and stores a log withthe modified constant name, new value, username, and time stamp of the mostrecent change.

The Strip Chartfunction (Figure 33) emulates a 10-pen strip chart recorder. Thescreen can display real-time data for up to 10 variables selected by the operator.Parameters are selected by assigning each pen a value; the values can beanalog or binary data available for monitoring. Each pen can be assigned adifferent color, line weight, and symbol to easily distinguish different monitoredvalues from one another. The bottom of the strip chart screen displays thecorresponding legend for each pen. Each of the plots is scaled for the selectedvariable and displays the actual numerical value for each variable. The daterange and scaling can be changed by double clicking on the desired pen to bringup the configuration pull-down menu. The time axis on the strip chart can be

configured for each pen by date, hours, minutes, or seconds. The "zoom" featureallows the user to zero in on the particular area of interest.

4.1.7 Further tools on the screens

Graphic screens offer further information such as:

The help on line. The main objects shown on the graphic screens theres the possibility toclick on it and understand the main characteristics of the object selected.

The advanced tag details. This feature is available for most of the analog indication.Clicking on the value, a pop-up window is opened showing all the object settings like set-points, bargraph, charts to have the history of the signal in a defined period and the help-

on line.

Figure 11. Advanced Tag Detail




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Figure 12. Operation Summary

Figure 13. Process Summary




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Figure 14. Engine Summary

Figure 15. Enclosure




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Figure 16. Operation Sequence

Figure 17. Control System




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Figure 18. Engine Vibrations

Figure 19. Generator Vibrations




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Figure 20. Lube Oil System

Figure 21. Fuel Gas System




22

Figure 22. Start System

Figure 23. Fuel Details




23

Figure 24. Engine Details

Figure 25. Lube Details




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Figure 26. Temperature Details

Figure 27. Advanced Vibrations




25

Figure 28. Maintenance

Figure 29. Alarm Log




26

Figure 30. Event Log

Figure 31. Historical Log




27

Figure 32. Constants

Figure 33. Strip Chart




28

Figure 34. Gas Turbine Performance Map




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4.1.8 Special Functions

Special display screens can be provided, but Turbomach must be consulted to determine

feasibility. Time required for programming, debugging, and documenting nonstandardinterface screens can be significant and should be evaluated carefully to determineproject cost and delivery impact.

4.2 TT4000 REMOTE

When remote monitoring and control is required from an additional location, an additionalTT4000 installation can be provided in a desktop PC. This remote TT4000 can interfacewith the primary TT4000 system either through an Ethernet or ControlNet network.




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5 Turbine Control

The control system provides extensive control and protection functions for the turbinepackage. Aspects of the turbine control are determined by the specific requirements of aparticular project. The following information is applicable for a typical gas fuel package.The four primary functions provided by the control system are:

Sequencing

Control

Protection

Display

5.1 SEQUENCING

The key elements of the sequencing function are:

Starting Loading

Stopping

Post Lube

5.1.1 Starting

The control system is armed by turning on the electrical power and, if necessary,resetting any alarms or shutdown malfunctions. The operating mode is selected,determining whether the system is controlled from localor remote.

Start is initiated by the operator and the following actions take place:

Lube oil pump is run through a test cycle.

Package enclosure fans are started.At the completion of this pre-crank check, the starter rotates the engine, developingairflow through the compressor to purge gas accumulated in the engine, air inlet, andexhaust duct. The length of the purge cycle is tailored to the exhaust duct volume for thespecific project. If the engine does not accelerate to meet a preset speed within aspecified time, the start sequence is aborted. Once the engine reached the crank speedand before starting the purge sequence, the pressure test is performed on the gas fuelvalves (starting in gas fuel). The valves are opened and closed in sequence with thestarting and stopping of timers and the fuel pressure signals are verified. If the test issuccessful the purge crank can start and during this phase the fuel valves are closed andthere is no ignition.

After completion of the purge cycle, when the engine has reached the required speed

and temperature levels, ignition takes place. A small amount of fuel is introduced into thecombustor from the gas torch and ignited by the igniter plug. Fuel from the fuel valve thenenters the combustor through the injectors. The fuel valve gradually ramps open. Fuelflow, engine temperature, and turbine speed all increase. If the engine temperature doesnot reach the light-off temperature set point before a specified time, ignition failure isannunciated and the start sequence is aborted.

When the turbine exceeds the starter speed, the clutch allows the starter to freewheeland when the turbine reaches starter dropout speed, the starter is de-energized and theengine continues to accelerate under its own power.




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5.1.2 Generator Loading

Loading the generator requires closing the generator circuit breaker. The circuit breakercan be closed to either a dead (de-energized) or hot (energized) bus. When the control

system detects a dead bus, the circuit breaker may be closed either manually orautomatically by the control system. When the system detects a hot bus, the generatormust be synchronized to the bus before the circuit breaker is closed. The control systemcan automatically synchronize the generator to the bus and close the breaker.

5.1.3 Stopping

The turbine may be shutdown either manually or automatically.

Manual Stops

Activating the Normal Stop command from the HMI results in a cooldown stop. Theturbine is unloaded and run at idle speed for a set time to allow the turbine to cool beforethe fuel valve is closed. Activating the Emergency Stop command (ESD push-buttons

from package skid) results in immediate unloading and fuel valve closure without acooldown period. In both cases, after the package has come to a complete stop and arundown timer has timed out, the post-lube cycle is started.

Automatic Stops

The control system automatically shuts the package down in response to specifichazardous or malfunction conditions. These shutdowns are divided into four categories:

Cooldown Stop Nonlockout (CN)

Cooldown Stop Lockout (CL)

Fast Stop Nonlockout (FN)

Fast Stop Lockout (FL)

The Cooldown and Fast Stops correspond to the Manual Normal and Emergency Stopsrespectively. The Lockout Stops inhibit operation of the control system and the systemcannot be restarted until the malfunction is reset. Lockout Stops generally result frommore serious malfunctions that require corrective action before the system can berestarted. The Nonlockout Stops typically result from an operation disruption or abnormalcondition and can be reset when conditions return to normal.

5.1.4 Post Lube

The control system initiates and supervises the post-lube cycle to protect the turbinebearings from thermal damage. The configuration of the pumps and the length of thepost-lube cycle depend on the turbine type and package design.

5.2 CONTROLOnce the package has completed the start sequence and steady-state operation isreached, the control system keeps the equipment within the specified operatingconditions. The minimum power limit is zero load and occurs for generators when thegenerator circuit breaker is open. The maximum power limit is established by the enginetemperature and by the speed. The generator or the main gearbox equipment may alsoplace upper limits on engine power output.

5.2.1 T5 Control

Turbine service life is directly related to the temperature at the first-stage turbine nozzle(T3). This high temperature, however, decreases thermocouple reliability. To improvethermocouple reliability, the temperature at the third-stage nozzle (T5) is measured.




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Multiple T5 thermocouples are used, the number being determined by the engine type.Control is based on the average T5 temperature. If one thermocouple reading varies fromthe average by more than a preset amount, an alarm is annunciated. If two or, in some

configurations, three vary by more than that amount, an alarm is annunciated and thepackage is shut down.

5.2.25.2.25.2.25.2.2 Speed Control

Speed pick-up probes continuously monitor the turbine speed and the control systemadjusts the speed to meet the operating requirements and to keep the speed within thespecified limits. Additional safety is provided by a separate backup overspeed detectionsystem that automatically shuts the engine down if the overspeed limit is reached.

5.3 PROTECTION

The control system provides extensive protection of the package by monitoring speed,temperatures, pressures and other variables. Most variables have limits that when

exceeded result in a response by the control system. Typically, one level triggers analarm and a second level triggers an automatic shutdown of the package as described inSection 5.1.3.

Alarm summaries and event logs are provided by the display system.

5.4 DISPLAY

Section 4 provides a detailed description of the Display and Monitoring System.




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6 Generator Control

In addition to monitoring the generator temperature and vibration levels, theTurbotronic

4control system includes extensive control and protection of the generator and its output,including regulation, synchronizing, and load sharing. The key component for this controlis the combination generator control module (CGCM). This device combines the linesynchronization module technology developed by Allen-Bradley with the digital automaticvoltage regulation technology developed by Basler Electric. The result is an extremelypowerful and versatile device that integrates readily into the control system by connectingto the systems ControlNet network. Figure 35 shows the typical connections required bythe CGCM for the management of two circuit breakers.

The CGCM provides four modes of regulation based on its voltage and current inputs. Itprovides the ability to synchronize the generator to one or two reference buses. It permitsoperation of the generator in either isochronous (isoch) or droop modes. In addition, itpermits load sharing between generator sets with similar control systems.

6.1 EXCITATION CONTROL MODES

Four modes of regulation are available:

Automatic Voltage Regulation (AVR) The output voltage of the generator is controlled.

Field Current Regulation (FCR) The field current to the generator is controlled.

Power Factor Regulation (PFR) The power factor of the paralleled machine is used todetermine the correct field current.

Reactive Power Regulation (VAR) The VAR output of the paralleled machine is used todetermine the correct field current.

EXCITATION OUTPUT

GENERATOR CB

BUS PLANT

EXCITATION POWER

LOAD SHARE LINES

(To other Combined Generator Control

Module or Load Share Module)

GENERATOR

ARMATURE

(Stationary)

GENERATOR FIELD

RECTIFIER

ASSEMBLY

EXCITER

ARMATURE

EXCITER FIELD

(Stationary)

GENERATOR

POTENTIAL

TRANSFORMERS

GENERATOR

CURRENT

TRANSFORMERS

CROSS CURRENT

COMPENSTATION

TRANSFORMER

BUS

POTENTIAL

TRANSFORMERS

GENERATOR

COMBINED GENERATOR CONTROL MODULE

CONTROLNETTo Turbotronic 4 Control Processor

AREP

ROTATING

PORTION

UTILITY

UTILITY CB

Figure 35. Typical CGCM Connections




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6.2 SYNCHRONIZATION

The CGCM can provide synchronization between two buses by measuring appropriate active busand synchronization parameters (Figure 36). Voltage matching between buses is also performedthrough measurement of these parameters. Control and error parameters are provided to thegenerator governor for bus synchronization and to the CGCM's internal voltage regulator forvoltage synchronization. The CGCM synchronizes the generator output voltage, frequency, andphase to a reference power system.

Figure 36. Process Summary Screen with Synchronization Pop-Up open

6.2.1 Dual Bus Connection

It is desirable to have the ability to synchronize a generator to more than one referencebus. Turbomach standard foresees synchronization at 2 different points (generator CBand Utility CB). The CGCM supports this operation by allowing connection to one phaseof two different buses. The appropriate bus for synchronization is selected automatically.When used in this manner, the three-phase output of the generator and a single phasefrom each reference bus should be connected to the CGCM. The CGCM cannotdetermine the phase rotation of either reference bus since only one phase is connected.Therefore, no phase rotation match can be performed. However, the correct phaserotation, ABC or ACB, can be configured in the device and the CGCM can then verify thatthe generator output phase rotation matches the configured data.

Supplementary Sync check & phase rotation relays are installed in order to allow theclosure of Gen CB or Utility CB.

6.3 LOAD SHARING

The system provides equal generator real power kW sharing for multiple generatorsoperating in parallel. The controls of the other generators must use the CGCM, the Allen-Bradley line synchronization module, or other compatible device. The load sharing linesof the CGCM are connected to the equivalent terminals on the parallel generatorscontrols. The generators then share load at an equal percentage of each generators totalcapacity.




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6.4 PROTECTION

Fourteen fault protection functions are provided as part of the CGCM as backupprotection of the main protection relays. Faults are communicated to the controlprocessor via the ControlNet interface. These fault conditions and the industry standardprotection codes, where applicable, are:

1. Field Current Limit

2. Generator Overcurrent (51)

3. Generator Overvoltage (59)

4. Generator Undervoltage (27)

5. Loss of Excitation Current

6. Loss of Operating Power (27)

7. Loss of Sensing (60FL)

8. Overexcitation Voltage (59F)

9. Overfrequency (81O)

10. Phase Rotation Error (47)

11. Reverse Power (32R)

12. Reverse VAR (40Q)

13. Rotating Diode Monitor

14. Underfrequency (81U)

For Generator protection, digital protections relays are provided as a standard in theTurbine control panel. These are protection relays in a 19 plug-in module design (4U), inwhich several protective functions are programmable:

Model ANSI code Description of the function

IDT8N 87T differential current protection

ING4N 50 / 51 over current for short circuit/overload

protection

46 unbalanced load protection

UAR4N 27 under-voltage protection

59 over-voltage protection59Uo stator earthing 95% (homopolar voltage)

PQR4N 32 reverse power protection

40 loss of excitation




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These protection features only protect the generator. As an option, Turbomach can offerusers power distribution system protection functions. These additional protectionfunctions will not be part of the CGCM, but part of additional hardware.

Model ANSI Code Description of the function

HAR1N 81 min./max. frequency

max. frequency rate of change df/dt

max voltage vector shift ()

UAR4N 27 min. voltage

59 max. voltage

59Uo voltage absence

6.5 KILOWATT CONTROLIn addition to the control modes listed in Section 6.1, the system can be programmed toprovide kilowatt control. This is useful when the generator is operating in parallel with alarge power source such as an electric utility. The kilowatt output of the generator can beset at any level within the capability of the unit.

In some cases, it may be necessary to prevent power from being imported from orexported to the utility when the preset output of the generator exceeds the utility loadrequirements. In this case, the system can be programmed to always import or export apreset amount of power.




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7 Supervisory Communications

In many cases, the turbomachinery and its controls are part of a larger plant or stationthat has an overall supervisory control and data acquisition (SCADA) system ordistributed control system (DCS). The Turbotronic 4 control system offers severalconnection options. Connection is directly to the control processor by means ofcommunication modules mounted in the processor rack.

7.1 DATA INTERFACE

The ControlLogix processor supports the full Control and Information Protocol (CIP).

To read the full tag names, the DCS must be CIP capable. Currently, this meanscommunicating with the unit control processor either using another ControlLogixprocessor or using a PC with Rockwell RSLinx software.

An available alternative to CIP are the protocols described in Section 7.2

7.2 COMMUNICATION PROTOCOLS

7.2.1 Modbus (Serial or TCP/IP)

The Modbus communication is granted adding a dedicated interface module.

The Modbus interface module allows Rockwell Automation ControlLogix processors tointerface easily with other Modbus protocol compatible devices. The interface moduleacts as a Modbus slave device to communicate with a Modbus master device providedby the user. The connection may be with an RS232C, RS422, or RS485 serial link cable,

or over Ethernet TCP/IP. Data are transmitted using a subset of the RTU version of theModbus protocol.

7.2.2 OPC

The OPC UA(unified architecture) is granted through a service running on both local andauxiliary HMI

The whole set of tags available to be displayed on the HMI screens can be accessed byexternal OPC UA clients connected to the server via Ethernet.

Support for legacy protocols such as OPC DA 2.0 may require the installation of

additional software components.




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8 Other Features and Options

8.1 SOFTWARE MODIFICATIONThere are two sets of project specific software in the Turbotronic 4 control system: theRSLogix 5000 control processor software and the TT4000 HMI software. Both can bemodified in the field by qualified service personnel.

Note: Software modification should be undertaken only with extreme caution, sincechanges may cause malfunctions with the potential for equipment damage and personalinjury. Equipment under warranty should only be serviced by authorized personnel fromTurbomach to prevent voiding of the warranty.

8.1.1 RSLogix 5000 Software

Modification of this software requires a licensed copy of the RSLogix 5000 masterprogram installed in a separate computer that is interfaced with the PLC through a

suitable connection. The software is installed on a portable laptop computer and thecommunication can be established either with a special PCMCIA type card and aControlNet connection cable or with a USB cable or with an Ethernet cable. This meansthat the connection does not have to be made directly to the control processor; it can beto any network adapter. A different card is available for installation in a desktop PC. Eachnetwork adapter on the Turbotronic 4 ControlNet network has an RJ-45 plug forconnecting the cable.

8.1.2 TT4000 Software

The TT4000 software operates in two different modes: Design Time and Run Time. TheDesign Time mode is used to create or modify the working files related to a specificproject. The Run Time mode uses those files in the normal operation of the equipment.

TT4000 is shipped with both modes available to the user. This allows the user to modifythe project files if necessary.

8.2 LANGUAGES FOR TT4000 DISPLAY

The TT4000 displays can be provided in dual language configurations, allowing the userto switch between English and another language. Available languages include thefollowing, but other language displays can be provided on a special order basis:

Spanish

Portuguese

French

German

Italian

Russian

Dutch

Turkish




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8.3 ENGINEERING UNITS

The TT4000 displays can be provided in either English or various Metric units:

English Metric

Pressure psig kPa bar kg/cm2

Temperature F C C C

Length inches mm mm mm

Flow Std. MMSCFD Msm3/d Msm

3/d Msm

3/d

Flow Act. ACFM m3/min m

3/min m

3/min

Head ft-lbf/lbm kJ/kg kJ/kg kJ/kg

8.4 PRINTERSA printer/logger option is available, which provides a dot matrix printer, for printing thealarm and shutdown log, one event per line. This allows the operator to review recentevent history.

Turbomach Turbotronic 4 Controls System Brochure - Rev J

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