Instrumentation & Control

Al Khobar Roadshow, 24 July 2006

Federico Calzolari
I&C Product Engineering
Contents - Steam Turbine Automation

• Introduction – Why a New Controller?

• Mechanical Governor Replacement
• Control System
• Protection System
• Additional Controls
• Turbine Supervision
• Remote Monitoring, Diagnostics
• Security
• Success Stories

2
Why a New Controller?

• Aging Controls
• Maintenance Activity
• Reliability issues
• Excellent cost/benefit ratio
• Reduction of operators’
intervention
• Spare parts
• Turbine Life Extension
• Possibility to Change Parameters

3
Mechanical Governor Replacement

• Mechanical Hydraulic Controller Replacement

– minimal actions on existing system, thanks to the
knowledge of the technology as original manufacturer
• Existing System
– Analysis
– Planning and engineering of proper action
• complete replacement of
control, protection and
supervisory systems
• adaptation of the existing
system to the new
operating requirements

4
Mechanical Governor Replacement
Example: Franco Tosi Turbine

5
Mechanical Governor Replacement
Example: Franco Tosi Turbine

6
Ansaldo Energia Solution

• To supply a steam turbine automation system that

provides a truly integrated solution
– Minimize the different types of hardware and software
– Minimize mechanical modification on the existing turbines
– Deliver information to operators and decision makers in a
single, consistent format

7
Steam Turbine Control System

• Steam Turbine Control System (STCS)

– Microprocessor-based distributed digital control system
• Designed for controlling and monitoring all types of steam
turbines
– Modular and flexible system
• Today’s control with tomorrow’s requirements
• Expandable
• Advanced control capabilities
– Independent system jointly developed with ABB Energy
Automation

8
Steam Turbine Control System
Main Functions

• STCS functions
– controlling
– sequence management
– data acquisition
– operating station
– data storage
– diagnostic
– interface with
external systems

9
 Steam Turbine Control System
Typical System Architecture

CLIENT
CLIENT
ANSALDO
ANSALDO REDUNDANT ETHERNET – TCP/IP OPC server protocol

Tenore NT
Laser Printer Tenore NT
Operator Station
Operator Station
PLANT
DISTRIBUTED Alarm Printer Configuration &
CONTROL Maintenance station
SYSTEM
Ethernet for Printers

C-NET (Redundant Control Network)

STEAM TURBINE CONTROL,

HARDWIRED MONITORING & PROTECTION
SYSTEM (STCS)

TSI Cabinet

Cabinet dimensions [mm]:

800 (W) x800 (D) x 2200 (H)

FIELD

10
Steam Turbine Protection System (1/2)

• The steam turbine tripping system comprises all the

logic necessary to protect the machine.

• During a retrofit it is necessary to coordinate the

mechanical and hydraulic modifications with the
electronic control system requirements.

11
 Steam Turbine Protection System (2/2)

PROTECTION CONDITIONS (examples):

- OUTLET PRESS. - LEVEL LUBE OIL TANK

- EXTRACTION PRESSURE - BEARING TEMP´s.

! Three channel, fail safe principle:
- LUBE OIL PRESS. - SHAFT - VIBRATION´s Trip, if more than 1-channel
deenergized
- SHAFT POSITION - BOILER PROT.

- THERM. STRESS - GEN. PROT. ! Triple sensors for the most

important protection
ELECTRICAL COMMANDS
FROM TTS ! Equal trip logic in each channel

! Independent electronic
overspeed trip

! Trip memory and resetting device

Pin Pout ! 2oo3 voting of the outputs via

Pressure SAFETY SYSTEM Pressure to el./hydr. Tripping - Unit
from lube oil 2oo3 - Hydraulic Tripping Unit servomotors
pump ! Online testing of all trip channels
(5-150 bar) via test program.

Normal Functioning Electrical commands from TTS ON P out = 5-150 bar

Trip Condition Electrical commands from TTS OFF P out = 0 bar

12
Steam Turbine Protection System
Overspeed Protection
• Mechanical Overspeed Trip
System
– Trip threshold imprecise,
analog system
– Fluctuating Trip threshold
– No trip indication
– No fault tolerance
– Dedicated tests required
during commissioning
• Electronic Overspeed Trip
System
– Trip threshold very precise,
digital system
– Steady Trip threshold
– Alarm indication on the
automation system
– 2 out of 3 voting
– Minimised start-up testing
13
Additional Controls
Functional Groups and Turbine Run Up

• Auxiliary Automation
(Functional Groups)
– Lube oil system
– Turning gear and
lifting oil system
– Draining system
– Gland steam system
– Control oil system

• Turbine Run Up (TRU)

– Automatic start-up & shutdown system
• Increase availability
• Avoid operator errors and aborted starts

14
Additional Controls
Thermal Stress Calculation

• Rotor Stress Evaluator (RSE)

for calculation of
– Turbine Thermal Stresses
– Gradient limits for starting-up
and loading
– Limit values for alarms
and trips

• Advantages
– Time saving during steam turbine start-up
– Economic saving during steam turbine start-up
– Easier operator supervision functions

15
Turbine Supervision
• Old steam turbines • New supervisory equipment
– Equipped with no
supervision
instrumentation
– Mechanical devices
detecting main variables
only
– Lower reliability
– Not only Electronics
– Feasibility study realized
with mechanical experts
– Design of the modifications
– On-site manufacturing
– Huge benefits in design
phase when OEM involved
16
Remote Monitoring, Diagnostics

• 2 diagnostic levels

– Basic diagnostic tools

• Integrated with the operator interface
• Basic Predictive Maintenance

– Advanced diagnostic systems

• Monitors the dynamic signals
• In depth analysis
• Advanced Predictive Maintenance with Technical Support

17
Basic Diagnostic Tool - Overview

• Allows continuous
information on the
machinery status

• Stores and processes field

data to create reports and
trends

• Overview at plant level,

plant local areas and
individual machinery

18
 Basic Diagnostic Tool
Re.M.S. (Remote Monitoring System)
Headquarter /
Client Hub Site
• Real time graphical operating
parameters and trends of
machines / plant
• Selection of various parameters
• Transfer of logic diagrams,
control parameters and settings
and system diagnostics
• Faster evaluation of possible
anomalies
• Improved commissioning
TENORE NT
• Tenore NT acquisisce,
elabora e visualizza le
informazioni sugli
allarmi attravers o
pagine grafiche e
tabulati ed indica
all’operatore come
acquisire ed utilizzare
tali informazioni.
1
19
Advanced Diagnostic System (1/2)

• Why Advanced Diagnostic System?

– Store and analyse data
– Perform quick and effective troubleshooting
– Improve Availability
– Clear and quick exchange of information with the Operator
– Technical support by Ansaldo

• TVA System
– The system for data collection and remote monitoring
– The solution for advanced predictive maintenance
• Rotor Vibrations
• GT & ST Run-up, Shut-down, Thermodynamic Parameters
• Generator Electric Parameters
• …

20
Advanced Diagnostic System (2/2)

Technical support to operating units

it works on 3 levels of competences:

- Expert Centre (Regional)

(functional diagnostic, support to Operator)

- Fact Finders and Specialists

(structural diagnostic, support to Maintenance)

- Product Engineering (Headquarter)

(design analysis, high level specialists)

21
 Advanced Diagnostic System:
Problem Solution

?
Power Plant Engineering
department

Solution
Expert Centre

22
Expert Centre

• Monitor multiple plants

simultaneously
POWER STATION POWER STATION

• Staff optimisation MODEM MODEM

• Concentrated OEM expertise

MAIN DIAGNOSTIC SITE

• Broad range of data mining

and advanced design and
MODEM MODE M

diagnostic tools
MODEM

POWER STATION POWER STATION

• Faster problem resolution

POWER STATION

23
Italian Remote Expert Centre:
TVA Connections

• Today: • Connections within 2006:

– ISAB PRIOLO – ENIPOWER BRINDISI
– ENIPOWER FERRERA – MONCALIERI
– ENIPOWER RAVENNA – SPARANISE
– CASSANO – LEINI
– ENIPOWER RAVENNA – ROSIGNANO
S.T. 60MW TD 300
– ENIPOWER MANTOVA
– VOGHERA
– ENIPOWER BRINDISI

24
Power Plant Security (1/3)

Melissa 26 March 1999 >= 100,000 hosts infected

CodeRed 19 July 2001 >= 350,000 hosts infected
Slammer 25 January 2003 >= 75,000 hosts infected
Blaster 11 August 2003 >= 500,000 hosts infected
Sasser 30 April 2004 >= 1,000,000 hosts infected

+500 new malicious programs per month worldwide

25
Power Plant Security (2/3)

• Plant security as industrial added value

– Industrial mission continuity
– Power plant availability

• Industrial plant security

– Attack/intrusion prevention
– Consequence minimization
– Key factor in evaluating
plant operational continuity

• Essential for critical infrastructures

– Power plants
– Electricity distribution
– Water Desalination

26
Power Plant Security (3/3)

• Global Security Program

– Physical security
– Logical security
– Operational security

• Power Plant Security

with an
integrated approach

27
Success Stories: TSI example

• Al Jubail Power Plant (SWCC)

– Turbine supervisory
instrumentation retrofit for
phase-1 (units 1-6)
• main turbine
• Generator
• F.D. fan
– Turbine supervisory instrumentation
retrofit for phase-2A (units 1-5)
• main turbine
• Generator
• BFP turbine

28
Success Stories:
Steam Turbine Control System Replacement

• Gela Refinery Power Plant (ENI Group)

– Franco Tosi 70 MW steam turbine with double controlled
extraction
• Complete replacement of Mechanical Hydraulic
Controller by new Digital Electro-Hydraulic Control
System
– Speed and load controller
– Turbine Tripping System
– Auxiliary System Automation
– Turbine Supervisory Instrumentation
– Automatic Run-up Sequence

29
Summary

• Ansaldo Energia own Technology

• New unit development applicable to retrofit any

turbine technology

• Effective and efficient

• State-of-the-art predictive approach to maintenance

30
Instrumentation & Control
Al Khobar Roadshow, 24 July 2006

Federico Calzolari
I&C Product Engineering