motivTCS Turbine Control Systems

Providing Engineered Controls Since 1997

motivTCS Turbine Control Systems

Appendix
Page Selection
1. 1. 1. 2. 3. 3. Introduction Key Features Applications Architecture Control Panel Protection System 3. 3. 3. 3. 4. 5. Backup ESD System Operating Condition Shutdown Sensor Fault Shutdowns Shutdown Modes

Fault Tolerant Design Control Modes 5. 5. 5. 6. 6. 6. 6. 6. 6. 6. 6. Start Permissives Sequencing Start Fuel Limit Accel Control Decel Control Gas Turbine Speed Control and Topping Governor Temperature Control Variable Geometry Control Droop Mode (Generator Only) Isochronous (Generator Only) Process Control

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motiv Data Tools 7. 7. 7. 7. 7. 7. Commissioning Tools Data Query Data Capture Data Scheduler Web Based Data Query Custom Data Solutions

motivTCS Turbine Control Systems

Introduction
Since 1997 Tarco has proven that it is one of the most highly respected industrial automation and turbine control companies in the world. Our commitment to the constant advancement and innovation of our control system continues to set us apart from the competition. Incorporating over 200 years of cumulative experience in turbine controls engineering, design and operation, we believe there is no better turbine control system in the marketplace than our motivTCS. Tarcos line of motiv products are running 24/7 on hundreds of systems around the world.

Applications
The motivTCS is inherently modular and can therefore be applied to virtually any turbine in any application. Other benefits of this modular approach: Reduce costs by tailoring the system to the application. System can easily be expanded to support future upgrades. For example, the system can be configured to support a legacy fire and gas system but can be expanded in the future when the system is upgraded.

Key Features
Proven off-the-shelf industry standard hardware (AB, GE, Siemens) Industry standard programming languages (IEC Ladder, Function Block, etc) Simplex or fully fault tolerant redundant systems Support for dual fuel configuration Variable geometry control Support for various applications: compressor, pump, generator, chiller etc. Configurable for unique applications (e.g. dual turbine power generation) Backup ESD system Backup over speed system Support for all industry standard communication protocols Color touch screen display Point Level diagnostics

The motivTCS system is available for all brands of turbines and their driven components. Tarco has successful installations on GE, Mitsubishi, Lycoming, Pratt & Whitney, Rolls Royce, Ruston, Solar, Kawasakiand more.

motivTCS Turbine Control Systems

The motivTCS system is configurable for a variety of applications: Generator Installation o Stand-Alone o Black Start o Utility Bus o Load Sharing o Excitation o Synchronization Compressor Installation o Gas o Refrigeration o Dry Seals Pump Installation o Pipeline Transfer o Water Injection

Architecture
The motivTCS uses only off-the-shelf industry standard components. The benefits of this are: - Spare parts are readily available - Reduced training costs: the same hardware is used elsewhere in the plant. Technicians are often already familiar with the hardware. - TCS System uses industry standard programming languages (e.g. ladder logic, statement list, function block) making the system easy to diagnose and monitor. - The motivTCS control system can be configured to any control platform. The TCS system is available on the following platforms: Allen Bradley, GE, Siemens as well as others. - TCS System supports all the major industry standard communication protocols: o o o o o o Modbus Serial/TCP Profibus ControlNet DataHighway bearing temperatures, etc. EGD (Ethernet Global Data) Ethernet IP

The motivTCS system is configurable for the integration and control of a wide variety of auxiliary systems: Lube Oil Systems Cooling Systems Surge Control Systems Vibration Systems Integration Fuel Valves Systems Servo Valve Systems: Fuel, IGV, Bleeds, etc. Steam/Water Injection Systems Fire & Gas Detection Systems Fire Suppression Systems Combustion Flame Detection Systems

Selected motivTCS models are designed to directly replace the following legacy fuel control systems: Hawker Sidley Woodward 501, 511 and Netcon 5000 GE Mark II to VI

All hardware supports multiple input and output signals: o o o o o o o o mA Signals mV Signals Digital Inputs/Outputs Thermocouples RTD Speed Probes LVDT Fiber Optics

motivTCS Turbine Control Systems

Control Panel
The motivTCS control panel uses industry standard components that are readily available throughout the world. Customizable panel interface can be fitted with pushbuttons and switches for major operator functions such as start, stop and speed control.

The motivTCS system comes equipped with various levels of equipment protection features. Backup ESD System The backup ESD system is a hardwired relay system independent of the main control system. In the event of an overspeed condition or user activated shutdown, the backup ESD system will override any signals from the main control system and immediately isolate fuel to the turbine. As an option, the system comes equipped with an API 670 compliant triple redundant backup overspeed protection system. Operating Condition Shutdowns During operation the motivTCS is continuously monitoring live sensors such as oil temperatures, oil pressures, vibration and many more. The system will trigger an alarm if the sensor exceeds the alarm limit. If the sensor exceeds the shutdown limit the system will immediately stop the unit. Sensor Fault Shutdowns Sensors are continually monitored for a fault condition. Critical non-redundant sensors will automatically trigger a shutdown if the sensor faults (e.g. Lube oil pressure). The system will alarm only if there is a redundant sensor.

motivTCS double-wide panel

Protection System
The motivTCS system in normal operating conditions will control the turbine to maintain the process requirements (e.g. Generator Speed, Discharge and Suction Pressure, etc). This system automatically changes control loops to protect the OEMs specified tolerances while continually maximizing performance.
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Shutdown modes In the event of a serious malfunction, the control system objective is to minimize crashstops that reduce the life of the gas turbine. The following describes the different types of shutdowns: 1. SDN Shutdown Non-Lockout: If a SDN is detected, fuel is immediately cut to the engine, causing a crash stop. A SDN can be reset remotely if the control panel is in REMOTE mode. 2. SDL - Shutdown Lockout: If a SDL is detected, fuel is immediately cut to the engine, causing a crash stop. A SDL cannot be reset remotely. SDL-type shutdowns must be reset locally.

motivTCS Turbine Control Systems

3. ESD - Emergency Shutdown: An ESD operates similar to a SDL. The difference between the two is that an ESD is also relayed to an external plant control system (if applicable) in order to shutdown any systems that interface to the turbine control system or turbine skid. An ESD cannot be reset remotely. In compressor applications, an ESD also initiates a compressor blowdown. 4. CSN - Coolstop Shutdown: The generator or other driven equipment will be slowly unloaded and brought back to idle speed. The unit will sit at idle for a configurable cooldown time before shutting down. 5. STI - Step-To-Idle: The unit will be unloaded and brought back to minimum loaded speed. In generator applications, the breaker will also be opened in order to avoid reverse power conditions.

Fault Detection: If the system detects a module fault, the relay is opened automatically to interrupt power to the affected module Pulse Test: Outputs are periodically pulsed to confirm functionality. Single or Dual Transmitters Reference Test: Accommodates periodic testing of the A/D converters by switching the input channels from the field devices to known, on-board reference voltages. Faulted sensors will alarm but not trigger a shutdown to avoid a spurious trip. Each analog input pair can be configured for 1oo3 or 2oo3 or 3oo3 voting. o 1003: If all three sensors are healthy, a shutdown will occur if 1 of the sensors exceeds the shutdown limit. Configurable shutdown time delay to allow fault to register. 2003: If all three sensors are healthy, a shutdown will occur only if two sensors exceed the shutdown limit. 3003: If all three sensors are healthy, a shutdown will occur if all three sensors exceed shutdown limits.

Fault Tolerant Design

The motivTCS control philosophy is to protect the machine and, when possible, prevent spurious trips. This results in the highest availability possible for the selected design configuration. All motivTCS systems come with following fault tolerant design features: Point level diagnostics: The system detects the type of fault on a specific channel (e.g. analog under range) and details the exact condition on the graphic display. Maintain SIL2 Fail Safe Requirements Module fault will not cause a shutdown Periodically the relay is pulsed from an output module

Fault tolerant packages available: 1. Simplex I/O with Diagnostics 2. Simplex I/O, Redundant CPU 3. Fully Redundant: Power Supplies, Controllers, Communication Modules, Communication Wiring, Chassis, I/O Modules, Fuel Valves

motivTCS Turbine Control Systems

Control Modes
The motivTCS comes equipped with various control modes in place to protect the machine and maintain the required operating condition. Following is a list of the primary models: Start Permissives The system verifies all systems are ready to go before a start is permitted. Examples of checks are: - Turbine is not rotating - No shutdowns are active - No permissive alarms are active (e.g. MCC in Manual) Sequencing The system provides complete start-up and shutdown sequencing as well as interface to all auxiliary systems such as motor control centers, switchgear, and facility controllers. During the start sequence, auxiliary systems are automatically started and verified to be operational before the turbine is cranked and fuel is emitted to the engine. After ignition is established and idle speed is achieved, a warm-up period is allowed before load is applied.

All sequence steps are clearly displayed on a start-up screen along with associated timers and setpoints. For example: during oil system pressurization, 30 seconds might be allowed to establish oil pressure after the pump is started. In this case, the timer is shown as well as the actual oil pressure and the setpoint oil pressure. If the timer reaches zero before the oil pressure reaches the setpoint, a shutdown is initiated. If the oil pressure reaches the setpoint before the timer expires, the startup continues to the next sequence step. All sequence timers and setpoints can be configured from the Operator Interface Terminal after entering a user-defined password. Start Fuel Limit The start fuel control is in effect from the moment fuel is initially applied to the engine until engine idle speed has been achieved. The start ramp can be completely configured from the display. Up to two start ramps can be configured to allow for dual fuel applications.

motivTCS Lube Oil Screenshot

motivTCS Overview Screenshot

motivTCS Turbine Control Systems

Accel Control The Acceleration limiter ensures that fuel flow allowed to the engine does not increase at a rate faster than that allowed by the increase of engine CDP. This prevents over-fuelling of the engine and increases the life of the hot section components, but should not normally be in control of the fuel valve. Decel Control The Deceleration limiter ensures that fuel flow allowed to the engine does not decrease at a rate faster than that allowed by the decrease of engine CDP. This prevents under-fuelling of the engine and flame-out, but should not normally be in control of the fuel valve. Gas Turbine Speed Control and Topping Governor The speed control and topping governor is typically in effect after the unit reaches the configured idle speed. On single shaft units, speed control will also be in effect during loading and while online. It is possible to bias the maximum speed setpoint based on ambient temperature by using the ambient biasing schedule detailed in the following sections. This is a method of limiting output power at low ambient temperatures. Temperature Control The TE limiter ensures that the maximum permissible gas temperature at entry to the turbine section is not exceeded. The TE setpoint can be biased with respect to ambient temperature in order to limit engine output power at low ambient temperatures. In generator DROOP mode or in all compressor/pump applications, it is normal for the TE limiter to be in effect anytime the unit is running online, especially on hot days.

motivTCS Turbine Temperature Screenshot Variable Geometry Control The system can be configured to control inlet guide vanes, variable bleed valves and variable stator vanes. Droop Mode (Generator Only) Speed droop is used to control the magnitude of governor response for a given frequency change so all generators will share response after a disturbance. Isochronous Mode (Generator Only) This control mode is used on generators where the output frequency is held constant regardless of load. Process Control The system can be configured to limit on external process conditions such as discharge pressure control.

motivTCS Turbine Control Systems

motiv Data Tools

Software designed for commissioning, data acquisition and trending of turbine data.

rate is required. This program can be customized to meet your data capture requirements. motiv Data Scheduler The motiv Data Scheduler utility works with historic data stores to perform recurring data transfer tasks that are very easy to configure and maintain. Data transformations have never been this easy. There are currently four transfer types supported: data transfer from a source database to a destination database; FTP transfer from a source database to a FTP site folder; by exception data transfer from a source database to a destination database and data archive. The tool can be customized to allow other recurring historic data handling requirements. motiv Web Based Data Query The motiv Web Based Data Query allows browsers such as Internet Explorer to query data from the data store. Multiple tags can be queried from multiple devices from multiple locations. The system allows disparate historic data stores to be queried with the outcome combined into a single resultant data set. The resultant dataset can be presented as a trend complete with scroll and zoom options. Custom Data Solutions Tarco provides customization of the Data Tools or the creation of new utilities. Our areas of expertise cover database technologies, data analysis, data reporting and custom software modules. We have a vast array of experience with handling realtime and historic data.

motiv Commissioning Tools The motiv Commissioning Tools was designed for commissioning, debugging and live data reporting of control systems. The system performs the following tasks: Data Logging; Analog Trending; Discrete Trending; Data Set-Point Read/Write; Alarm Logging; Data Reporting and Snapshots. motiv Data Query The motiv Data Query was born from industry driven requirements to help solve problems associated with multiple Data Stores and Data Logs stored on numerous servers in various databases. Concentrating, querying, analyzing and managing these disparate data sources can be an arduous task. motiv Data Capture The motiv Data Capture utility is designed to capture and store time-stamped data as a recurring schedule. There are two data capture types - Data Capture and Data Logger. Data Capture is used where the recurring rate is more than 1 second between data captures. Data Logger is used where a higher rate or continuous capture
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motiv is a registered trademark of Tarco International Inc., registered in Canada and the U.S. All rights reserved.

motivTCS Turbine Control Systems

Tarco Systems Inc. Calgary, Alberta, Canada 3004 Ogden Road S.E. T2G 4N5 Phone 403.265.0955 Fax 403.265.0966 Toll Free 800.590.7815 info@tarco.com www.tarco.com