maxDNA Integrated Turbine

Control

Youjun Xu
maxDNA integrates the boiler and turbine
control into a total Plant Automation System….
• Common operator interface
• Integrated operations reporting and logging
• Reduced overall capital cost
• Fewer spare parts
• Simplified maintenance
• Single interface to ADS
• Common coordinated boiler-turbine control
• Flexibility - ease of expansion
• Common configuration tool set

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Key features of maxDNA turbine control…

• Automatic speed control - faster, safer startups

• Automatic load control - linearizes response and
provides smooth, faster load changes
• Plant Constraint Coordinator - load changes made
at fastest allowable rate
• DPU4F and valve positioning card - high speed
processing and valve positioning
• Redundant 2-out-of-3 speed measurement and trip
modules - protects turbine from single point of failure
• Version 4.0 operating system - high security,
Windows XP and remote diagnostic access
• Separate, redundant control and protection
partitions - improves plant reliability and availability

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 Functions provided through the operator’s
workstations …
• Speed control In/Out
• Impulse pressure control In/Out
• Megawatt control In/Out
• Adjustable settings for …valve position limits, runback limits and
rates, acceleration and MW rate
• Test of throttle, governor and reheat/intercept valves
• Display of all valve positions
• Transfer full arc to/from partial arc mode
• Reference, demand and MW displays
• Go/Hold modes for speed or load control
•…

© Metso
 maxDNA Turbine Control System Configuration
(DF) Operator
WorkStation
Engineer
WorkStation

maxNET

Turbine Auto-Start
Operator Turbine
Auto Control Control
I/O Bus I/O Bus

Frequency Hydraulic
Counter Input Servo ×1 ×4 ×2
&Over Speed Interface
Trip Cards Cards ••• •••
Process Process
OR I/O I/O
Speed ≥103%
Close Intercepts
Stop Control Valve Position
Valve Valve
OR Actuator Actuator Demand
And Feedback
Speed Steam Interceptor
Stop
≥110% Stop Valve Valve
Control
Trip Turbine Valve Valve Actuator Actuator

Turbine High
Intermediate Low Pressure Generator
Pressure
Speed Pressure
Speed
Signals Transducer
Reheater
Stop
Valve

© Metso
 maxDNA Turbine Control System Configuration
(DF) Operator
Engineer
WorkStation
WorkStation

maxNET

Turbine Auto-Start
Operator Turbine
Auto Control Control
I/O Bus I/O Bus

Frequency Hydraulic
Counter Input Servo ×1 ×4 ×2
&Over Speed Interface
Trip Cards Cards ••• •••
Process Process
I/O I/O

Stop Control Valve Position

Valve Valve
Actuator Actuator Demand
And Feedback
Steam Interceptor
Stop
Stop Control Valve Valve
Valve Valve Actuator Actuator

Turbine High
Intermediate Low Pressure Generator
Pressure
Speed Pressure
Speed
Signals Transducer
Reheater
Stop
Valve

© Metso
 maxDNA MEH Control System Configuration
Operator Engineer
WorkStation WorkStation

maxNET

BFP BFP
Operator Operator
Auto Control Auto Control
I/O Bus I/O Bus

Frequency
Frequency ••• Counter
•••
Counter Hydraulic Hydraulic
Servo Process Input Servo Process
Input
Interface I/O &Over OR Interface I/O
&Over OR
Cards Speed Cards
Speed Speed ≥103%
Speed ≥103% Trip Cards
Trip Cards Close Close
HP LP HP LP
Valve Position Valve Valve
Valve Position
Valve Valve
OR Actuator Actuator Demand OR Actuator Actuator Demand
And Feedback And Feedback
Speed Steam Speed Steam
≥110% ≥110%
Trip Turbine Trip Turbine LP
LP HP
HP Valve
Valve Valve
Valve Turbine
Turbine Intermediate Intermediate
Pressure Speed Pressure
Speed Speed Speed
Transducer Signals Transducer
Signals

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maxDNA Turbine Control Reference in China
• 国电荥阳电厂2x600MW (DF) • 京海电厂2x300MW (DF)
• 马鞍山第三电厂2x660MW(HTC) • 三河电厂二期2x300MW( DF)
• 江西丰城电厂二期2x660MW(STC) • 古城电厂2x300MW (STC)
• 襄樊电厂2x600MW(STC) • 昆明二电厂2x300MW (
• 宝山电厂2x660MW(STC) • 宣威电厂七期2x300MW(DF)
• 章丘电厂2x300MW() • 宣威电厂六期2x300MW(DF)
• 小龙潭电厂2x300MW(DF) • 贵溪电厂2x300MW(STC)

• 田家庵电厂300MW(STC) • 鸭溪电厂2x300MW()

• 闵行电厂2x125MW • 巡检司电厂2x300MW/1x135MW
• 宜宾电厂100MW
• 昆明电厂100MW

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 maxDNA Turbine control overview graphic

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maxDNA Turbine control overview graphic
( STC&HTC)

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maxDNA Turbine control overview graphic
DEA(DongFang)

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maxDNA Turbine Control Module

• Valve Positioner
IOP341

• Overspeed Trip
IOP345

• PLU
IOP348

DPU4F maxPAC Terminal Panel

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 Programmable module
Use with SW Development tools

Store the configuration

Mix of I/O in on board flash
Write the program
4 AI, 4 AO, 8 DI, 8 DO
Very High Speed
5 ms AI, 5 ms AO
5 ms Program Cycle 4 x AI 4 x AO
Times maxPAC Bus
Programmable
Compiled IF/ELSE/ENDIF
Let 8 x DI
8 x DO
Flexible Terminations 24 VDC
DIN Mounted Relay
Smart Module maxDPU4F
Different Varieties
Not a product by itself - it is a
building block

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 maxDNA Turbine Control Module
Valve Positioner IOP341
• Each valve shall have its own control card
• Control card shall provide redundant outputs to a servo
• Outputs are (-)10V to 0 to (+)10V DC, 40ma, 4-20ma
• Servo has two coils in parallel (80 to 120 ohms)
• Failure of one coil shall not effect operation
• Valve control card shall be able to operate in full arc and partial arc
modes
• Operator shall be able to independently test and calibrate any
throttle or governor valve on-line without effecting load
• Alarms shall be provided to the operator upon a malfunction of a
LVDT or servo

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LVDT position feedback …

• Two LVDTs or other position feedback device shall be

provided for each valve
• Excitation shall be provided
• Load resistance is 500 ohms
• Demodulated signal shall be compared to valve position
demand on board the control card
• Recalculation of the position demand signal shall be at
least every five milliseconds
• Operator shall have the ability to do a null check of the
LVDT (linearization program)

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Typical Turbine Control Hydraulic Equipment

maxPAC
Hydraulic
Servo
I/O
Module

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k
 Turbine Control Valve Interface …

Demodulator

Stop Or
Control
Valve
Position
Demand

Servo Servo
K + ∫∫ Actuator LVDT
_ Amp Valve

Position
Transducer

Dump
Filter
Valve

Isolation
Valve

High Pressure Drain OPC and Emergency Trip

Fluid Supply
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 Signals
to/from Turbine Valve Positioner Module
DPU

Position
Status
Pos.

Dual
Valve > Position
Position Feedback

Pos.

High Select

Servo
Amp
Dual
Outputs
Valve
Position K+∫ to
Servomotor
Demand
Coils
Servo
Tuning Amp
Constants

Coil
Status

Speed Freq. Turbine

Signal Speed
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 Valve Position Demand Computation...
Turbine
Speed

K+ ∫ Σ f(x)
Stop
Valve
K Position
Demand
(N) (N) (N)
Reference (Y) (Y) (Y)
T Σ Σ T K+ ∫ T > f(x)
Control
Main Breaker First Stage Partial
Valve
Closed Pressure Arc
Position
Inserted Admission
Droop K K+ ∫ Turbine Valve Demand
First Stage Position
Pressure Limit

Speed
Ref. Generator
MW

Turbine
Speed …executed every 10 ms in DPU
Frequency Bias

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 maxPAC Turbine control response features

maxDNA Turbine
valve positioner：
Average response
time: 14ms

Date © Metso Title/Author

 maxDNA Turbine Valve Positioner response
features Test with Harbin Turbine Works

Date © Metso Title/Author

 maxDNA Turbine Valve Positioner response
features Test with STC FCB(fast cut back)
Function
• Sequence
valves;

• critical cycle
time: 10ms

• response time：
30.871ms

© Metso
 maxDNA Turbine Valve Positioner response
features Test with STC FCB(fast cut back)
Function
• Single valve;

• critical cycle
time: 20ms

• response time ：
41.123ms

© Metso
 Dong Fang Turbine
--1 MSV, 4 CVs, 2 ICVs
Stop Control
Valves Valves
Steam
Supply
Intermediate
High Pressure Pressure Low Pressure Generator
Actuator Actuator RH Stop
SX PT Valve MW
Intercept
Reheater
Valve
Speed 1st Stage
Pressure Actuator Actuator

High
Pressure
Steam
Trip

Turbine Control Turbine Protection

* Auto Start-up * Overspeed Trips
* Speed Control * Hydraulic Oil High Pressure Hydraulic Oil System
* Synchronization * Lube Oil * Valve Operator
* Generation Control * Low Vacuum * Servos
* Speed Sensors * Load Rejection Anticipation * Position Xducers
* Speed Sensors
Date © Metso Title/Author
Dong Fang Turbine Valve Positioner

Normal AI + 10ms FB + Fast AO + DF Valve Card

Average response time: 171ms+

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Dong Fang Turbine Valve Positioner
response features

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Dong Fang DEH：Integrated into maxDNA…

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maxDNA Turbine Control Module
Overspeed Trip IOP345

•Software stored in FLASH

•Fast frequency measurements
•Field to logic isolation
•Fast scan time
•On-line diagnostics
•Downloadable personality
• It provides signal conditioning and optical isolation for the
three frequency inputs and provides 5-volt square waves to
the module.
• Two form C relay outputs are included.

© Metso
 Signals Turbine Overspeed Protection
to/from
DPU

Speed Turbine
Signals F Speed
and Pulses
Status

Median
Select

H// 103%
Overspeed
Overspeed
Trip
Settings 110%
H//
Overspeed

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 maxDNA Turbine Control integrate ETS
Configuration 1

IOP 345
Channel 1
Counter Input

IOP 345
Channel 2
Counter Input

ops relay logic

IOP 345
Channel 3
Counter Input

Turbine trip
Solenoid valves

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maxDNA Turbine Control integrate ETS
Configuration 2

Speed ≥103%
OR Close Intercepts

Speed ≥110%
OR Trip Turbine

ops relay logic

Turbine trip
Solenoid valves

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maxDNA Turbine Control Module
Specifications
 Frequency Input:
• Frequency Range: 100Hz - 10KHz
• Accuracy (FastF1 value): +/- 3Hz from 100Hz - 5KHz +/-15Hz
from 5.001KHz – 10KHz.
• Passive Sensor Input: 0.2Vrms to 10Vrms
• Active Sensor Input: 0VDC/24VDC @ 10mA (bi-level input)
• Isolation: The three frequency inputs are optically isolated
from the DPU.
• The three inputs share a common field supply and field
ground.
Digital Output
• Form C Relay 5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC 。
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maxDNA Turbine Control Module
PLU IOP348
•The Power Load Unbalance (PLU) is designed
to protect against turbine overspeed.
•This mode will only be activated if the turbine undergoes a
large load rejection.
•The power of the turbine is measured by cold reheat pressure
(first stage LP turbine inlet pressure) while the load of the
generator, is measured by the generator’s current.
•PLU Runback actions will occur only when the power load
unbalance is greater than 40% the generator experiences a
sudden load rejection of more than 2000%/sec.
•The power load unbalance runback is used to energize the
fast-acting solenoids on the control and intercept valves,
respectively. The power load unbalance signal for the intercept
valves is only active for one second, allowing the intercept
valves to re-open after one second.
© Metso
PLU Protection Logic
Cold RH Steam Pressure Power Load Unbalance > 40%
Norm H Runback
Turbine Power to
Valve
Electrical Load
Position
Comparison
Demand
Generator Normalized
40% A
Current Values Power Surge
> 2000% per sec L
A
N + dx Current Rate H O Enable PLU
B dt of Change
G
N Xducers OK I
C C
N A 2000% per sec A
SS IV Solenoid
1
Minimum Current > 2000A Sec IV Solenoid
Current H Current > 2000A
2000 Amps A & Speed > 3000 RPM CV Solenoid
N
Speed > 3000RPM D CV Solenoid
Median H O
R
PLU Runback CV Solenoid
O
R
20% per sec CV Solenoid
3000RPM A A
Speed
Signal
1 dx
dt
H A
2 / 3 High
Acceleration
N
D
H
A
N
A A D
Speed
Signal
2 dx
dt
H A
N
D
H
High Acceleration
A
O Alarm
N
R
A A D
Speed
Signal
3 dx
dt
H A
N
D
H
A
N
A D

© Metso
 PLU LOGIC (Technical Document)
Once activated, the maxDNA® TCS will:
1. Activate PLU Runback Signal (Alarm).
2. Energize the Intercept valves fast-acting solenoids
for a timed period (1-10 second typically). The
Intercept valves will re-open after a timed period.
3. Energize the Control valves fast-acting solenoids
until PLU Runback is cleared.
4. Set the Control valves position demand to zero until
PLU Runback is cleared.
5. Force the Governor Position Demand Mode to
MANUAL.
6. Set the Valve Position Demand to minimum load.
7. Holds fast PA to FA mode, until PLU Runback is
cleared.
The following items will disable this function.
1. Loss of transducers.
© Metso 2. Turbine speed less than 3000 RPM.
3. Generator current less than 2000 Amps.
 PLU Logic (Power Load Un-Balance)

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 PLU Logic (Power Load Un-Balance)
// Compute Average of Generator Current
fGenCurrentAvg = ((GenCurrent1 + GenCurrent2 + GenCurrent3) * fCurrentNormalizationFactor) / 3
// Compute Delta Turbine Power To Electical Load
// Note: The order of the subtraction is very important
If (bInputsAreGood = True)
fPowerToLoadDelta = fNormColdRHStmPress - fGenCurrentAvg
If (fPowerToLoadDelta > fPowerToLoadHiLim)
bPowerToLoadLimExceeded = True
EndIf
EndIf
AStat03 = fPowerToLoadDelta
// Determine if Current Rate Of change Limit Exceeded
// Since all the Inputs are already in % there is no need to calculate the % of change
If (iQualGenCurrents = Good)
If (iLastQualGenCurrents = Good)
fGenCurrentRateOfChange = (fLastGenCurrentAvg - fGenCurrentAvg) / Elapsed
//
If (fGenCurrentRateOfChange > fCurrentRateOfChangeHiLim)
bGenCurrentRateOfChangeLimExceeded = True
EndIf
EndIf
// Determine if Current value Exceeds its limit
// The fCurrentHiLim is a % that corresponds to 2000Amps
If (fGenCurrentAvg > fCurrentHiLim)
© Metso bGenCurrentLimExceeded = True
EndIf
Other Needs ...

• Turbine test simulator

• Rotor stress monitor program
• Auto turbine startup program
• Standard set of turbine control graphics
• Standard set of reports and with history
• Optimum speed program to ensure demand is not in blade
resonance range
• Optimum valve position program to ensure valves are positioned for
maximum efficiency
• Standard EH equipment list for easy quoting

© Metso
Startup & Loading Profile for Turbine …
note that transfer to partial arc admission on GE
machine occurs only after unit is synchronized.

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 40

maxDNA Turbine Control Startup Curve

(2008.11.29)Turbine Turbine Speed Switching
Speed Setpoint Valve
(2900 RPM)

3000 RPM

Speed
Ramping TV
Demand
GV
Demand

© Metso
Integrated maxDNA Turbine Control Summary
• Redundant partitions for control and protection that provide for
highest reliability and faster, safer startups
• Individual valve control provides the ability to control at optimum
valve points and test each valve
• Highly responsive actuators that do not stick and operate in linear
fashion
• Linear response to generation demand that allows units to move
at highest permissible rate of change
• Common HMI allows operators to respond faster and get more
information on turbine
• Integrated alarm, reporting and event summary for entire plant
operations - see all events relative to each other using same time
standard

© Metso