GTG SGT 700 control system

1. PRESENTED BY: Nikhil Kumar
Assistant Manager
Instrumentation

2. INDEX
• GTG Control System
• Control Cubical Overview
• UCP
• TCP
• GCP
• MDS
• MCC
• Control System Components
• Control System Architecture
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• Control(Profibus-DP) network
• Unit Control Panel
• Turbine Control Panel
• Generator Control Panel
• Multi Drive System & Motor
Control Center
• Remote IO Panel
• Fieldbus (Profibus-PA) network
• Ethernet network
• Control network
• CCR(HMI & accessories)
network

3. GTG CONTROL SYSTEM
• The control system is built up around standard micro-computer based
products from the Simatic PCS7 family of integrated and distributed
control systems (DCS) for industrial automation.
• The type of process stations used is the S7-400 series.
• Programming language is the SFC (sequential function chart) and CFC
(continuous function chart), function block languages with graphic
presentation also integrating in the WinCC operator station. The SFC and
CFC are specially oriented to process control.
• Together with various dedicated front end systems, the PCS7 hardware and
standard gas turbine application software constitutes the control system.
The controllers transfer mainly all instrumentation signals of the gas turbine
to the operator station.
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5. CONTROL CUBICLE OVERVIEW
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6. Control cubicle CJD11
This control cubical is Unit Control Panel for GT. In UCP the programmable
process controller is located. There are total two controllers AS1 and AS2.
The functions of AS1 are supervise, automate and sequencing including:
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• Starting
• Loading
• Unloading
• Stopping
• Cooling down
• Set value generation voltage regulator
• Turbine Governing
• Frequency control at synchronizing
• Frequency/load control
• Load limiting
• Load rejections
• Flame sustaining control
• Bleed valve 1 and 2 control
• Inlet guide vane control (IGV)
• Compressor control
• Separation gas
• Seal gas
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8. The AS2 have control over the Safety and Protection System. The shutdowns
are implemented with relevant SIL level, according to the performed SIL study.
CPU, PROFIBUS and safety related outputs are classified as SIL3.Types of
shut down are as follows:
GT Start Abort - Instant closing of fuel shut off valves and stop of start
sequence. Valid only during start-up. Start Aborts are considered lower priority
than the other types of trips and are in general only 1oo1 evaluated.
GT Unload 30 – The gas turbine is unloaded with a ramp corresponding to 30s
from full to minimum load. The fuel shut off valves are closed when reaching
minimum load or after 30s from the time of failure. If the failure clears during
the unloading, the ramping is stopped and the turbine is kept in operation at the
present load.
GT Unload 90 – The gas turbine is unloaded with a ramp corresponding to 90s
from full to minimum load. The fuel shut off valves are closed when reaching
minimum load or after 90s from the time of failure. If the failure clears during
the unloading, the ramping is stopped and the turbine is kept in operation at the
present load.
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GT ESD – Instant closing of fuel shut off valves.
GCB ESD - Instant opening of Generator Circuit Breaker. Depending on
the severity of the faults these trips can also cause the GT to trip and in
some cases the Field Circuit Breaker (FCB) to open. GCB ESD trips
generated by the control system are hardwired to the trip coils of the GCB.
Most GCB ESD trips are generated in the relay protection system that
opens the GCB/FCB without going through the control system. Messages
from the relay protection are sent by PROFIBUS to the PLC for indication.
WinCC is the interface between the operator and the controllers AS1 &
AS2 for controlling the gas turbine.
The communication with the HMI and the machinery monitoring and
protection system is through Industrial Ethernet (TCP/IP). The
communication with the distributed I/O, AVR and relay protection is
through Profibus.
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Control cubicle CJP11
This control cubical is also called Turbine control Panel. The TCP contains
electronics for the turbine control like flame detector, speed modules, the
machinery monitoring system for vibration and axial displacement together
with the distributed I/O signals for the gas turbine protection system.
Control cubicle CHA11
This control cubical is Generator Control Panel for GT. The GCP contains
generator control and protection system consisting of protection of AC
Generator (relay protection), synchronizing equipment, automatic voltage
regulator (AVR) and the manual field current regulator (FCR). The AVR
and the FCR are located in the generator main terminal box. The
communication with the AS1 controller is through Profibus for changing
the set points, their automatic follow up and the automatic change over
between AVR and FCR.
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Control cubicle BFA
The control cubicle BFA handles the low voltage Motor Control Centre (MCC)
and the small power distribution. The MCC serves all the auxiliary systems in
the gas turbine package and all signals is connected via Simatic distributed I/O
that is placed in the MCC.
Control cubicle BPD
The purpose of the system is to give the correct current, frequency and voltage
to the motors in order to operate the gas turbine correctly. This cubical contains
MDS (Motor Drive System) for following systems:
• BPD12: Containing a drive for the starter motor
• BPD13: Containing line supply module
• BPD14: Containing line supply module
• BPD15: Containing drives for ventilation, gas fuel, IGV
• BPD16: Containing drives for the lube oil system
• BPD17: Containing the UPS, UPS-distribution, battery charger(s) etc.

13. GTG CONTROL SYSTEM
COMPONENTS
Siemens make SIMATIC PCS 7 control system is used to control the
startup, operation and safe shut down of GTG. following components are
used in PCS 7 control system:
• CPU: 410-5H
• Communication Cards: ET 200M, ET 200is and CP 443-1
• Power Supplies: S7-400, ET 200, Phoneix
• I/O cards
• PCS 7 applications
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14. CPU 410-5H
The CPU 410-5H is the latest generation controller specifically designed
for the SIMATIC PCS 7 control system. Specifications are as follows:
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• 5 Interfaces:
• 2X PN
• 2X for Sync Modules
• 1X Profibus DP
• CPU Speed: 450 MHz
• CPU Processing time: 10 ms to 5s
individually adjustable
• Memory: 48 Mb max, depending
on the SEC card used
• Protocols supported: TCP/IP, ISO-
TCP, UDP, Foundation
Fieldbus(via DP/FF Link),
Modbus

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16. CPU for this project comes with redundant fault tolerant in two racks
configuration. The synchronization modules are used to link the two CPUs.
They are installed in the CPUs and interconnected by means of 1 meter long
fiber-optic cables. The operation of a CPU 410-5H requires a system
expansion card. The system expansion card specifies the maximum number
of process objects that can be loaded to the CPU and saves the license
information in case of a system expansion.
The input/output modules of the SIMATIC S7 with the CPU 410-5H is
distributed via Profibus DP. I/O modules are used in single channel switched
configuration. In the single-channel switched distributed configuration, there
is a single set of the I/O modules, but they can be addressed by both
subsystems.
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19. DISTRIBUTED IO
The ET 200M distributed I/O station consists of
• IM 153 interface modules for connecting through PROFIBUS DP with
data transfer rates up to 12 Mbit/s
• Up to 12 I/O modules for connecting the sensor/actuator technology
ET 200iSP is an intrinsically-safe distributed I/O system with IP30 degree of
protection and can be used in areas where explosion protection is required
according to ATEX: II 2 G (1) GD Eex de [ia/ib] IIC T4. An ET 200iSP
distributed I/O station can consist of:
• 2 Power Supply modules
• 2 interface modules for data transfer through Profibus RS 485-IS with
the transfer rate up to 1.5 Mbit/s
• up to 32 I/O modules for connecting the sensor/actuator technology
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ET 200iSP
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ET 200M

23. PCS 7 APPLICATIONS
• SIMATIC Manager – the central application of PCS 7. From here you
open all other applications in which you must enter settings for the
PCS 7 project. You will set up your entire project from SIMATIC
Manager.
• HW Config – configuration of all hardware of a system, e.g., CPUs,
power supply, communications processors.
• CFC editor and SFC editor - creation of continuous function charts
(CFC) and sequential control systems.
• PCS 7 OS in conjunction with various editors - Implementation of
OS configuration.
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24. DISPLAYS
There are following types of displays:
Process Displays Graphic displays are created for the applicable processes, often
in the form of mimics. From these displays, the operator normally controls the unit.
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25. Trend Displays All analogue signals shown on the operators screen are archived.
Sample time is 1-2 s. Values are stored for appx. one month and uses 30 GB on the
operator station hard drive. The measured values which have been archived can be
graphically presented on the operator’s station
Alarm List The alarm list presents the last 1000 alarms and shut downs of the alarm
log, in the alarm archive appx. 250 000 alarms are stored. Each alarm is time tagged
with a 1ms resolution.as trend displays.
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26. SYSTEM ARCHITECTURE
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RMS
Controller-1 Controller-2 ES/OSC-1 ES/OSC-2 OSS
OSS
STDBY OSC
Printer-1 Printer-2
Plant Bus
Terminal Bus

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CONTROL NETWORK OVERVIEW

28. UCP CONTROL NETWORK
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C1P C1R
P R
C2P C2R P R
Y Link Y Link
Y Link Y Link
To
TCP
To
RIO
Node:11
Node:12
C1
C2

29. TCP CONTROL NETWORK
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P R
Node:23
P R
Node:27
P R
Node:22
From
UCP
C1
C2
Node 39
in MCC
(BFA21)
To
GCP
C1
C2
Profibus PA to field
JB for fieldbus

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GCP CONTROL NETWORK
P R
Node:41 Node:43 Node:47 Node:51 Node:55
P R P R P R P R
P R
Node:40
From
TCP
C1
C2
To
MDS
C1
C2

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MDS CONTROL NETWORK
P R
Node:71 Node:73 Node:75 Node:77
P R P R P R
P R
Node:70
Convert
Profibus to
ethernet
Convert
Profibus to
ethernet
Convert
Profibus to
ethernet
To LMS
Node:101&103
TO LMS To LMS
Node:107&109 Node:113&115
From
GCP
C1
C2

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RIO PANEL CONTROL NETWORK
Y Link Y Link
Y Link Y Link P R
Node:86
C1
C2
P R
Node:81
P R
Node:83
P R
Node:91
P R
Node:88
P R
Node:92
P R
Node:90
From
UCP

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FIELD BUS NETWORK
Fieldbus cable
(Profibus PA) from
TCP

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ETHERNET CONTROL NETWORK
To DCS
To Engr Room

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CCR ETHERNET NETWORK
From
Controller
Plant Bus Plant Bus Terminal Bus
Terminal Bus
Eng cum Op Stn-1 Eng cum Op Stn-2
Op Stn Client
Op Stn Server-1 Op Stn Server-2

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