PART I

505E TURBINE CONTROL

&

TURBINE INTERLOCK SYSTEM

KEBB 2X150 TPH + 1X32MW COAL BASED POWER PLANT

PT. PETROKIMIA GRESIK, EAST JAVA

PREPARED BY :

NAME : ARIPIN

HP: 081320009898

EMAIL : aripinxyz@yahoo.com

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PAGE : 1 of 14

505E TURBINE CONTROL

The 505E is 32 bit microprocessor based control to control speed ( or load) turbine and steam extraction turbine.

Turbine Control Device : Type : 505E

Version : 2.06-6A

Manufacturer : WOOWARD, FORT COLLINS CO, USA.

Electrical Configuration :

1. Power Supply input : 24 VDC (18 32VDC, 77VA max, 6.25A internal fuse) 2. Signal for HP Servo valve : 1 point, 4-20mA 3. Signal for LP Servo valve : 1 point, 4-20mA 4. Analog Input point : 6 points, 4-20mA 5. Analog Output point : 6 points, 4-20mA 6. Digital Input point : 16 points, 18 26VDC 2.5mA. 7. Digital output point : 8 points (NO/NC). 8. Aux. Power : 7 points, 24VDC 200mA max. 9. Speed Sensor input : 2 points (MPU = passive, Proximity Probe = active) 10. Serial Communication Ports : 2 ports (Modbus communication : RS-232, RS-422, RS485)

FUNCTION OF BUTTON

1. PRGM (Program) : to change all parameter (shutdown mode)

2. RUN : to Activate the 505E

3. STOP : to deactivate the 505E (once verification is given)

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acerText Box3

acerText Box505E Version 2.06-6A

4. RESET : to clear all alarm

5. F1 (Alarm) : to display any alarm

6. F2 (over speed test enable) : command for over speed test.

7. F3 : (Not Programmed)

8. F4 : to enable or disable extraction, Light ON Extraction Active.

9. SCROLL : Push the button left rigt, up down to display the parameter what do you want.

10. SELECT : push the button up or down to select current display (@)

11. ADJ : to up or down the parameter (Run Mode)

12. NO (0) : enter 0 or NO button to disable our command

13. YES (1) : enter 1 or YES button to enable our command

14. ACTR (2) : to display current actuator position (Run Mode)

15. CONT (3) : to display the parameter which is in control (Run Mode)

16. CAS (4) : (Not Programmed)

17. RMT (5) : Remote speed set point control information (Run Mode)

18. LMTR (6) : to display the valve limiter information (Run Mode)

19. Speed (7) : to display current speed & setting (Run Mode)

20. AUX (8) : (Auxiliary,Not Programmed)

21. KW (9) : to display current KW & Speed (Run Mode)

22. CLEAR : Clear Program / Run Mode entries, and takes to main display

23. EXT/ADM : Enter a decimal point or displays the extraction information (Run Mode)

24. DYN : Accesses the dynamic setting of the parameter controlling the actuator position (Run Mode)

25. ENTER : Enter new values in the program mode. And allows the direct entry of the setpoint values in the run mode.

26. EMERGENCY STOP : Emergency Shutdown command for the control.

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PAGE : 4 of 14

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SPEED PID OPERATIONAL MODE

The Speed PID operates in one of the following modes, depending on configuration and system conditions :

1. Speed Control ------- > Gen. And Utility Breaker are open 2. Frequency Control ---- > Gen. Breaker is Closed, and Utility Breaker is open (Single Running) 3. Unit load Control ----- > Gen. Breaker and Utility Breaker are Closed (Synchrone Running)

- Turbine HP and LP valve position control - Generator Load Control

NOTE : in KEBB Petrokimia, signal indication for Utility Breaker is looped (jump) with Generator Breaker.

When not programmed for Generator application, the 505E speed PID operates in a speed control mode at all times. When programmed for Generator application, the state of the Generator and utility breaked determine the operational mode of the speed PID.

If the Generator breaker is OPEN, the speed PID operates in a SPEED CONTROL MODE.

If the Generator breaker is CLOSED, and the utility breaker is open, the FREQUENCY CONTROL MODE is selected.

When Generator breaker and utility breaker are close, a UNIT LOAD CONTROL MODE is selected.

While in the Speed Control Mode, the Speed PID will control a turbine at the same speed or frequency regardless of the load its supplying ( up to the units load capability). With this configuration, no form of droop or second controlling parameter (KW signal) is used by the PID for stability or control.

The Unit Load PID have 2 (two) parameters to control unit load and act as a stabilizing effect for any change in bus / utility frequency. With this configuration, when bus frequency decrease or increase, unit load increase or decrease respectively.

F (frequency) ------- > kW (Load)

F (frequency) ------- > kW (Load)

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3000rpm

0

3210rpm

SP

EE

D S

ETTING

Actual Frequency set by the utility (+/- 50H

z)

50% Load

100% Load

kW LO

AD

FRE

QU

ENC

Y IS SE

T BY TH

E U

TILITY G

RID

/ PLN

LOA

D V

AR

IES

WITH

SPEED SET PO

INT

(FRE

QU

EN

CY

AN

D LO

AD R

ELATION

SHIP)

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acerText Box3180rpm

acerText Box+/- 50Hz

+-

PID

TOO

UTP

UT

0%E

RR

OR

1. SP

EE

D C

ON

TRO

L

SPE

ED S

ET PO

INT (U

P TO

3000RPM

)

TUR

BINE

SPE

ED (3000R

PM)

+-

PID

5% of

Rated speed

AND

0%E

RR

OR

DR

OP

CA

LC

SPE

ED S

ET PO

INT (U

P TO

3210RPM

)

TUR

BINE

SPE

ED (3000R

PM)

UTILITY

BR

EAKER

GEN

. BREA

KER

2. TUR

BIN

E IN

LET V

ALV

E P

OS

ITION

CO

NTR

OL W

ITH FR

EQ

UE

NC

Y S

WITC

H ----> S

ING

LE R

UN

NIN

G

TOO

UTP

UT

-

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acerText Box

+-

PID

5% of

Rated speed

+-

PID

5% of

Rated speed

AN

D

0%ER

RO

R

AN

D

0%ER

RO

R

DR

OP C

ALC

DR

OP C

ALC

SP

EE

D S

ET P

OIN

T (UP

TO 3210R

PM

)

TUR

BIN

E S

PE

ED

(3000RP

M)

UTILITY

BR

EA

KE

RG

EN

. BR

EA

KE

R

TOO

UTPU

T

UTILITY

BR

EA

KE

RG

EN

. BR

EA

KE

R

GE

N. K

W

SP

EE

D S

ET P

OIN

T (UP

TO 3210R

PM

)

TUR

BIN

E S

PE

ED

(3000RP

M)

TOO

UTPU

T

3. GE

NE

RA

TOR

LOA

D C

ON

TRO

L WITH

FRE

QU

EN

CY

SW

ITCH

AN

D K

W FE

ED

BA

CK

-----> SY

INC

HR

ON

E R

UN

NIN

G

--

3. GE

NE

RA

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LOA

D C

ON

TRO

L WITH

FRE

QU

EN

CY

SW

ITCH

-----> SY

NC

HR

ON

E R

UN

NIN

G

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acerText Box4.

AC

TUA

TOR

-SERVO

3000RPM

TUR

BINE

SPEED

VALVE

LIMITER

INLET M

OTO

RIZED

VALVE

MAN

UA

L START M

OD

E

100%

0%

TIME

(EXAM

PLE : PAN

ASIA PO

WER

PLANT) Q

UIC

K C

LOSE

/HY

DR

AULIC

VALV

E FULLY O

PEN

AN

D BYP

ASS VA

LVE

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AC

TUA

TOR

-SERVO

3000RPM

TUR

BINE

SPEED

VALVE

LIMITER

SEM

I AUTO

MA

TIC STAR

T MO

DE

100%

0%

TIME

(EXAM

PLE : KEBB

PETR

OKIM

IA POW

ER PLAN

T)

QU

ICK

CLO

SE /H

YD

RAU

LIC VA

LVE FU

LLY OPEN

INLET M

OTO

RIZED

VALVE

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TURBINE START

The 505E has 3 (three) turbine start mode : 1. Manual Mode

2. Semi Automatic Mode

3. Automatic Mode

1. Check Turbine accessories ( example : EH Control Oil Pressure, Inlet Motorized Valve, Drain Valve, etc) or All important parameter to allow turbine start up. if OK --- > go to 505E.

2. Start Permissive - Open the Quick Closed Valve/ Hydraulic Valve ( Right and Left) untill fully Open, and the

limit switch will contact and send signal to 505E and DCS ----- > Fully Open - Click the 505 Run Permission Button on the Turbine & Gen Display DCS Computer,

and click YES.

3. Push RESET button - All alarms must be cleared, push the ALARM (F1) button to check alarm list if the button

is LIGHT ON (RED). - If alarm still appear, check the parameter and interlock switch. The interlocked

parameter must in safe range, and the not important parameter switch while the turbine start must be open (example : Generator Protection Switch, Vacuum protection, extraction protection).

- 505E will ramp open the LP valve ( Extraction Valve) to fully open 100%. And the HP valve ( Inlet Turbine Valve) still in the position fully close 0 %.

4. Push RUN button - The 505E in RUN mode will control the Turbine speed. - The HP Valve (Governor) will ramp open to minimum speed setting --- > 600 rpm. - And, Set the speed according to the Turbine Star up Chart.

5. Setting The Speed - Push the SPEED Button (7)

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- Push ENTER button Insert New Value Setting ( example : 12 00), and the push ENTER button.

ACTIVATE EXTRACTION NO. 2 IN 505E

1. Check Extraction No. 2 line ( Motorized Valve, drain Valve, etc.) to allow extraction no. 2 active / enable. If ready, go to 505E to enable the extraction no. 2.

2. Push F4, and then 3. Push YES /1 button to enable the Extraction. The display will change from disabled to

enabled, and F4 button will light on (red colour).

PAGE : 12 of 14

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SPEED VS EXTRACTION PRIORITY

Because an 505E has 2 (two) valve must be controlled ( Governor Inlet valve and Steam Extraction ). 505E can control 2 (two) parameter at a time. If the turbine reaches an operating limit, the result is only free moving valve to control with, thus the 505E can only control 1 (one) parameter.

In KEBB Petrokimia, Speed Priority is programmed. The 505E will only control turbine speed/load When the turbine reaches an operating limit. When programmed for speed priority, the 505E will maintain speed/load and sacrifice extraction control. With this configuration the Extraction PID is forced to lose control of its process.

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A. ENCLOSED DRAWING :

1. Control Oil HE Flow Chart 2. 505E wiring Diagram for DI/DO Points 3. 505E wiring Diagram for AI/AO Points 4. Turbine Hot Well Control Diagram 5. Turbine Alarm & Trip Setting 6. Turbine Shutdown Logic Diagram

B. ENCLOSED VIDEO : 1. 505E Button Fuction 2. 505E RUN and Speed Setting 3. 505E Extraction Activation / Deactivation 4. 505E Service Mode

PAGE : 14 of 14

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LAMPIRAN : 1 of 6K

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LAMPIRAN : 2 of 6K

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LAMPIRAN : 3 of 6K

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LAMPIRAN : 4 of 6K

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B P

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550 mm

or 850 mm

150 mm

or 450 mm

35%

8.3MP

a or 9.0 MP

a

0.89MP

a or 1.49 MP

a

-0.65 MP

a

0.13MP

a, DC

oil start

0.65MP

a, HP

pump S

tart

10.5MP

a

510C or 540C

3210rpm

95C

95C

95C

95C

95C

80C

70C

70C

70C

60C

80m

-0.6mm

or 0.6mm

20%

0.79MP

a

-0.45MP

a

0.08MP

a

0.3MP

a

9.6MP

a

110C

110C

110C

110C

110C

100C

100C

100C

120m

-0.8mm

or 0.08mm

Spdt

LAMPIRAN : 5 of 6K

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B P

T. PE

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acerText Box> 14.0Mpa -----> pump A STOP

< 10.5Mpa -----> pump A START

jika pressure masih rendah dari :

< 10.0MPa -----> pump B START ( 2 motor A & B START)

acerText Box

120m

120m

01505E TURBINE CONTROL 1.pdfCONFIGURATION OF CONTROL.pdf505E TURBINE CONTROL 2.pdfFREQ AND LOAD RELATIONSHIP.pdfPID1.pdfPID2.pdfMANUAL START.pdfSEMI AUTO START.pdf505E TURBINE CONTROL3.pdf

23dwg1.pdfdwg2.pdfdwg3.pdfdwg4.pdfdwg5.pdfdwg6.pdf