10-1435 sulzer-guaracachi santacruzbolivia tech report

TECHNICAL REPORT

MKV / 6FA COMBINED CYCLE UPGRADE &

DLN TUNING

UNITS: GTG-9, 10 & 11

prepared for

SULZER TURBO SERVICES ARGENTINA, SA (Guaracachi)

Santa Cruz, Bolivia

Issued: October 26, 2010

Project No. 2010-65-1435

Prepared by: William Stewart

Turbine Technology Services 12661 Challenger Parkway, Suite 250

Orlando, FL 32826

Sulzer Turbo Services Argentina, SA Project No. 2010-65-1435 EGSA Guaracachi / Santa Cruz, Bolivia Page 2

General Information .................................................................................................................. 1

Site Background & Purpose of Visit ........................................................................................ 2

Objectives. ................................................................................................................................. 3

Conclusions & Recommendations .......................................................................................... 4

Attachments Simple To Combined Cycle MKV Control Changes Turbine Boiler Protection Flowchart


1. GENERAL INFORMATION Customer: Sulzer Turbo Services Argentina, SA Site / Location: EGSA Guaracachi / Santa Cruz, Bolivia Customer Reps: Augusto Valdivia, Antonio Lanza, Esteban Aguayo TTS Site Personnel: William Stewart Timeline: 12th thru 20th October 2010

2. SITE BACKGROUND & PURPOSE OF VISIT The first subject turbine is a gas fuelled 6FA unit at Guaracachi, Santa Cruz, Bolivia. The unit being identified as GCH-11 was installed with a Mark V TMR Speedtronic control system. The other subject turbines are also gas fuelled 6FA units at Guaracachi, Santa Cruz, Bolivia. The units being identified as GCH-10 and GCH-11 Mark V TMR Speedtronic control systems. These units have recently been converted from simple cycle to combined cycle modes of operation. The first purpose of this Turbine Technology Services Corporation (TTSC) visit was to perform a DLN tuning exercise after mechanical rework of the unit GCH-11. The second purpose of this visit was to make the controls modifications to the combined cycle units (GCH-09 and GCH-10) followed by testing and DLN tuning as per an agreed scope of work proposed by Sulzer/TTS.

3. OBJECTIVES

3.1. Mechanical Objectives Install and configure the customers DLN tuning kit.

3.2. Control & Instrumentation Objectives The control and instrumentation objective was to perform a DLN tuning exercise after mechanical rework of the unit GCH-11. The second purpose of this visit was to make the controls modifications to the combined cycle units (GCH-09 and GCH-10) followed by testing and DLN tuning as per an agreed scope of work proposed by Sulzer/TTS.

3.3. Time Line of Works Carried Out

Monday 11th October 2010

Started travel from Orlando to Santa Cruz, Bolivia.

Tuesday 12th October 2010

Arrived at Santa Cruz airport at 8:30AM. Arrived at site around 1PM. Had a quick meeting with the customer and Sulzer rep to confirm the scope of work on unit 11. Began installation of the


DLN tuning kit on unit 11 around 2:30PM. After installation it was seen that no dynamics were being received from the unit. Changed the configuration from the default system left by the previous GTE engineer (equipment manufacturer) to the new conversion factors for the installed tubing length. Still no dynamics were being transmitted to the DLN computer. Left site at 6:30PM Contacted TTS DLN expert to confirm that the numbers in the configuration were correct.

Wednesday 13th October 2010

Arrived at site at 8:00AM. Tried several other program configurations but in every case no dynamics were seen by the system. The tuning purge box has 7 channels with 7 transmiiters. The 6FA only has six combustors so the spare from channel 7 was swapped with the transmitter in channel 6. Still no dynamics were seen. The correct nitrogen bottle and regulator became available at 3PM. All channels were purged with 200 psi Nitrogen, but still no dynamics were present. A frequency source was requested and this was used to inject all of the channels. The test signal was set to 300mV pk-pk @ 100Hz and was injected directly into the signal conditioner. All channels were working and displayed between 4 and 5 psi at 100 Hz. The same signal was injected at the other end of the sensor cables at the purge box and again all 6 channels showed 4-5 psi @ 100Hz. Next the connectors were removed from the sensors and the same signal injected and the system again displayed the correct numbers. This proved that the tuning equipment was fully functional from the transmitter outputs to the monitoring computer. All connectors on the transmitters were removed, cleaned, and replaced. Still no unit dynamics were being sensed. The conclusion is that either all sensors are non-functional or the DLN tubing is incorrectly installed. Developed the DLN spreadsheet in preparation for the tuning process. Left site at 6:45PM

Thursday 14th October 2010

Arrived at site at 8:00AM. Moved the complete DLN tuning kit to Unit 9 and purged all the PCBs and tubes with 200 psi Nitrogen. Again no dynamics were being sensed on this unit so still neither bad sensors or bad tubing installations can be ruled out. It was decided that the Sulzer rep would travel to Brazil and take 7 sensors from another tuning kit. It is expected that his return will be around Saturday. Started working on the combined cycle control code change requirements for unit 9. Had a meeting with the Customer/DCS engineer (Esteban) to discuss how the interface should work. A list of interconnections was generated together with a list of extra signals that the customer would like to receive from the MKV controller. Left site at 6:00PM


Friday 15th October 2010

Arrived at site at 8:00AM. Reviewed an old DLN tuning kit that the customer had in their stores, however it was only a wave-guide purging system and contained no PCB sensors. Continued working on engineering modification documents for units 9 and 10. Transmitted a standard boiler high temperature protection algorithm for review and incorporation into the customers DCS system. Created a flowchart showing how the unit will initially react to the DCS signals mentioned in the high temperature protection algorithm and transmitted this to the customer. Created a MKV connection list for DCS interface and transmitted to the customer. Left Site At 6:00PM

Saturday 16th October 2010

Arrived at site at 8:00AM. Sulzer rep returned with replacement pressure sensors for the tuning kit. Replaced two of the sensors but still no dynamics were being sensed. Moved the tuning kit to the last unit (GCH10) and although a very small signal was being detected by the tuning kit on channel 5, there was no real improvement. Called the equipment supplier GTE (John Brooks) and discussed the issues we were having and what local testing we had performed. He is also of the opinion that the tuning kit is operational and that the issue appears to lie between the PCB sensors and the combustion chamber. Initial discussions with site/Sulzer mechanical personnel indicated that the DLN waveguide sensors may be installed flush with the liner and not recessed by 0.062 as required. It is anticipated that the next step will be to shut down one of the units to check the probe insertions. Left site at 2:00PM.

Monday 18th October 2010

Arrived at site at 8:00AM. Meeting with customer highlighted several points that would inhibit the continuation of the work. Customer advised that they wanted a new exhaust temperature control curve generated. This task required the services of external sources. Data was requested from TTS engineering in order to generate this new exhaust temperature control curve. All data was provided from site with the exception of the exhaust pressure/ambient temperature data when the the units were running at base load. Currently due to the non completion of the heat recovery system, running at base load is currently not possible. This information will be required to be forwarded by the customer to TTS engineering at a future date. Also, no DLN tuning is currently possible due to the non-functionality of the tuning equipment/probe installation. Due to these reasons, the customer has no intentions to shut down the unit to only partially complete the scope of work. Left site at 6:00PM


Tuesday 19th October 2010

Awaiting demobilization details from Sulzer/Guaracachi. Continued working on the engineering documents for the future MKV changes required to support the combined cycle operation.

Wednesday 20th October 2010

Awaiting demobilization details from Sulzer/Guaracachi. Continued working on and completed the engineering documents for the future MKV changes required to support the combined cycle operation. This document was transmitted to TTS engineering for review and comment. Wrote the site visit report and transmitted this to TTS.

Thursday 21st October 2010

Demobilization from assignment and travel back to Orlando.

4. CONCLUSIONS AND RECOMMENDATION 4.1. Obtain a replacement DLN tuning kit and/or verify insertion depths of all sensors installed in

the units.

4.2. Obtain the following information from site :

a) Exhaust gas pressure and ambient temperature when units GCH-09 and GCH-10 can achieve base load.

b) Volume of previous exhaust duct and volume of newly installed boiler duct to calculate new purge times.

4.3. Obtain the following from TTS engineering :

a) New exhaust temperature control curves. b) New values for turbine start-up purge constants. c) New values for exhaust pressure switches 63EA-1, 63ET-1 and 63ET-2.


Simple to Combined Cycle MKV Control Changes UNIT GCH09 and GCH10 MKV Modification Requirements OTSG High Temperature Protection and Addition of Customer Requested Outputs. IO.ASG L4CT already exists. Ensure any required OTSG/steam turbine trips are incorporated into this signal. LCA4_FSNL Reset unit to FSNL Trip 52G (CIM) LCA70_RB Runback Command From OTSG Protection (CIM) S3 Turbine Complete Sequence To DCS N.O. S52GX1 Generator Breaker Status To DCS N.O. SITE.ASG :Added for OTSG High Temperature Protection (November 2010) ?LQ L52GT_TRIP3 LOG ; High-High Steam Temperature - Trip Gen Breaker ?LQ L70L_RB LOG ; High Steam Temperature - Load Runback Required ?LQ LTTGT_RB LOG ; Exhaust Gas Temperature Runback Required ?VQCC TTKGT_RB TC ; Exhaust Gas Temperature Runback Set-point ?LQ L83AMX LOG ; Auxiliary to L83AM ?VQ TTXM_OUT MWATT ; Exhaust Temperature Signal To DCS ?VQ TNH_RPM_OUT RPM ; Turbine Speed In RPM To DCS ?VQCC K3IGVTC_OFF DGA ; IGV Position Set-point For IGV Control OFF ?LQ L3IGVTC_OFF LOG ; IGV Position Permissive For IGV Control OFF CONST_Q.SRC : Added for OTSG High Temperature Protection (November 2010) TTKGT_RB 900 deg F ; Exhaust Gas Temperature Runback Set-point K3IGVTC_OFF 100.0 DGA ; IGV Position Set-point For IGV Control OFF Change TNKR1_5 as shown below TNKR1_5 0.67 %/min ; HIGH STEAM TEMP LOAD RUNBACK RATE Modify Purge Time Constants K2TV_1 (Hot Start) and K2TV_2 (Cold Start) to compensate for the larger volume in the OTSG duct. Currently set to 4.0 minutes and 2.0 minutes respectively. This needs information from customer. Need data on volume of old duct and volume of new duct. NOTE : Customer should have changed before now as the unit is running in combined cycle mode. Modify exhaust temperature control constants (TTKn_I, TTKn_C, TTKn_S and TTKRXBP) after the engineering study is complete. ALARM.LST 475 |LRB_ALM| GAS TURBINE LOAD RUNBACK 476 |L52GT_T3_ALM| GEN BREAKER TRIP FROM OTSG PROTECTION

Simple to Combined Cycle MKV Control Changes


ALARM.DAT QP 475 GAS TURBINE LOAD RUNBACK QP 476 GEN BREAKER TRIP FROM OTSG PROTECTION MAOUT_Q.SRC TTXM_OUT Q_C_MAO01 512 23551 ; 0 800 Deg C TNH_RPM_OUT Q_C_MAO02 0 23999 ; 0 6000 RPM Control Code Changes Add New Rungs OTSG High Temperature Protection CMP LTRUE Enable TTXM 0a LTTGT_RB ( ) TTKGT_RB 1b a>b LTTGT_RB -- Exhaust gas temp runback required LOGIC TTKGT_RB -- Exhaust gas temperature runback setpoint deg F TTXM -- Ex Temp Median Corrected by Average deg F LCA70_RB LTTGT_RB L52GX L70L_RB ( ) LRB_ALM ( ) L52GX -- Generator breaker closed LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC LCA70_RB -- Runback Command From OTSG Protection LOGIC LRB_ALM -- ALMTXT:'GAS TURBINE LOAD RUNBACK' LOGIC LTTGT_RB -- Exhaust gas temp runback required LOGIC L70L_RB L70LX3 ( ) L70LX3 -- Shutdown Lower LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC



Modify Existing Rung ADD L70RX5 L83MSPD L83MLOAD L83JD10 L83JD5 L83JD4 ////( ) L70LX5 L83SCI_ CMD L70HT SOK_L L84TL L70L_RB L3PMSV_TS / (Note L84TL Completely on Liquid Fuel - may be deleted for gas only units) L3PMSV_TS -- Primary GCV ref less than PGCV in PPM LOGIC L70HTSOK_L -- LOGIC L70LX5 -- High Temperature Spread Lower LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC L70RX5 -- Governor Raise Control Logical LOGIC L83JD10 -- FAST FIRED SHUTDOWN RATE SELECT LOGIC L83JD4 -- Auto Load Rate LOGIC L83MLOAD -- Manual Load LOGIC L83MSPD -- Manual Speed LOGIC L83SCI_CMD -- LOGIC COMMAND Isoch control LOGIC Add New Rung L70L_RB L3PMSV_TS L83JD10 L83JD5 //( ) L84TL (Note L84TL Completely on Liquid Fuel - may be deleted for gas only units) L3PMSV_TS -- Primary GCV ref less than PGCV in PPM LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC L83JD5 -- High Steam Temperature Runback Rate LOGIC L83JD10 -- FAST FIRED SHUTDOWN RATE SELECT LOGIC



Modify Existing Rungs L70LX2 L83SCI_CMD L33CDMN L70L //( ) L70LX3 (add L70LX3) L70LX4 L70LX5 L70LX6 L70LDLN L83SCI_CMD L60IL L70HT SOK_L L3HTSOKP / L33CDMN -- Droop Speed Setpoint at Min Limit LOGIC L3HTSOKP -- Comp heat soak perm to sync LOGIC L70HTSOK_L -- LOGIC L70L -- Lower Speed Setpoint LOGIC L70LDLN -- DLN Lower Load Signal LOGIC L70LX2 -- Base to Peak Transient Lower LOGIC L70LX3 -- Shutdown Lower LOGIC L70LX4 -- Local Manual Lower LOGIC L70LX5 -- High Temperature Spread Lower LOGIC L70LX6 -- Auto Synch Load Logical LOGIC L70TKL -- DWDROOP Setpoint Tracking Lower LOGIC L83SCI_CMD -- LOGIC COMMAND Isoch control LOGIC



L83SCI_ L70RX4 L30TXA CMD L70L L33CDMX LFSRCPR LCA70_RB L70R //////( ) L70RX5 L70RX6 L83SCI_ CMD L70TKR L30TXA -- ALMTXT:'EXHAUST TEMPERATURE HIGH' LOGIC L33CDMX -- Droop Speed Setpoint at Max Limit LOGIC L70L -- Lower Speed Setpoint LOGIC L70R -- Raise Speed Setpoint LOGIC L70RX4 -- Local Manual Raise LOGIC L70RX5 -- Governor Raise Control Logical LOGIC L70RX6 -- Load Rate #6 Logic Signal LOGIC L70TKR -- DWDROOP Setpoint Tracking Raise LOGIC L83SCI_CMD -- LOGIC COMMAND Isoch control LOGIC LCA70_RB -- Runback Command From OTSG Protection LOGIC LFSRCPR -- Comp Oper Limit Control Backup FSR Active LOGIC



L1S L94Y L14HS L83AM / ( ) L83SCI_ CMD L70R4L_R L83C L86MR1_ APCAN L83AM L94Z CPB / L70LDLN L3TN RERRX L30LTA L30GJL L70L_RB Break rung up and drive L83AMX with bottom 3 signals and use L83AMX in this rung. L14HS -- HP Speed - Min operating speed LOGIC L1S -- Auxiliary to Start Signal LOGIC L30GJL -- LOGIC L30LTA -- ALMTXT:'LOAD TUNNEL TEMPERATURE HIGH' LOGIC L3TNRERRX -- ALMTXT:'DWATT TOO LOW TO SUPPORT TNR-TNR LOWER' LOGIC L70LDLN -- DLN Lower Load Signal LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC L70R4L_R -- Operator Input Raise or Lower Speed Setpoint LOGIC L83AM -- Auto to Manual Load Transfer LOGIC L83CAPCAN -- Load Selection Cancel Logic LOGIC L83SCI_CMD -- LOGIC COMMAND Isoch control LOGIC L86MR1_CPB -- COMMAND PB Master reset LOGIC L94Y -- Time Delay Normal Shutdown LOGIC L94Z -- 4'S Up with No Shutdown LOGIC Add New Rung LCA4_FSNL L52GT_TRIP3 ( ) L52GT_T3_ALM ( ) L52GT_TRIP3 -- High-High steam temp trip gen breaker LOGIC L52GT_T3_ALM -- ALMTXT:GEN BREAKER TRIP FROM OTSG PROTECTION LOGIC LCA4_FSNL -- Reset unit to FSNL Trip 52G (DCS) [CA4-FSNL] LOGIC



Modify Existing Rungs

L14HS L52GT /( ) L32DW L52GT_ TRIP Add to L52GT_TRIP3 Existing Rung L14HS -- HP Speed - Min operating speed LOGIC L32DW -- Reverse Power - Generator Breaker Trip LOGIC L52GT -- Generator breaker trip [52GT-1] LOGIC L52GT_TRIP -- Mark V manual synch 52G breaker trip PB LOGIC L52GT_TRIP3 -- High-High steam temp trip gen breaker LOGIC L83PPBM_ L3FG_P2X L83FXPMZ L84TL L14HS CMD // ( ) L70L_RB L83FXP2 L83SCI_ CMD L83PPBM_ CMD L14HS -- HP Speed - Min operating speed LOGIC L3FG_P2X -- T.D. Above Estimated P3 Margin LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC L83FXP2 -- Premix Steady State Mode Selected LOGIC L83FXPMZ -- Not in Any Premix Mode LOGIC L83PPBM_CMD -- Piloted Premix Base Command LOGIC L83SCI_CMD -- LOGIC COMMAND Isoch control LOGIC L84TL -- Completely on Liquid Fuel LOGIC



Should the response of the load runback not be fast enough with IGV temperature control selected ON, then there is the further option to select IGV temperature control off. This selection can only be made at a very low load or when the IGVs are fully open. To prevent having to shut down the unit several times for test purposes, add the following rung and modify L43TVOFF as shown below. Prior to utilizing this function, full DLN mapping in IGV Temp Control OFF mode should be performed. Set the constant K3IGVTC_OFF initially to 100 DGA. If this IGV Temp Control OFF function is required, then this value can be reduced to 86 DGA. CMP LTRUE Enable CSGV 0a L3IGVTC_OFF ( ) K3IGVTC_OFF 1b a>b CSGV -- Position feedback IGV (high value selected) DGA K3IGVTC_OFF -- IGV Position Set-point For IGV Control OFF DGA L3IGVTC_OFF -- IGV Position Permissive For IGV Control OFF LOGIC L69T L43TVOF_ VOFDW CPB L43TVOFF ( ) L3IGV L60GVMAX TC_OFF L70L_RB L3IGVTC_OFF -- IGV Position Permissive For IGV Control OFF LOGIC L70L_RB -- High Steam Temperature - Load Runback Required LOGIC L43TVOFF -- IGV Temperature Control Off Select LOGIC L43TVOF_CPB -- IGV Temperature Control Off Pushbutton LOGIC L60GVMAX -- IGV at Maximum Position LOGIC L69TVOFDW -- Load Permissive to Turn IGV Temp Control Off LOGIC



Add New Rungs For Customer Requested Output Signals COPY LTRUE Enable Copy Analog LZZ ( ) TTXM 1input output0 TTXM_OUT TTXM -- Ex Temp Median Corrected by Average deg F TTXM_OUT -- Exhaust Temperature Signal To DCS deg F COPY LTRUE Enable Copy Analog LZZ ( ) TNH_RPM 1input output0 TNH_RPM_OUT TNH_RPM -- HP Turbine Speed (RPM) rpm TNH_RPM_OUT -- Turbine Speed In RPM To DCS rpm L3 S3 ( ) L3 -- Turbine Complete Sequence LOGIC S3 -- Turbine Complete Sequence To DCS LOGIC L52GX1 S52GX1 ( ) L52GX1 -- QD1-DTBB-027 Generator breaker status [52GX-1] LOGIC S52GX1 -- Generator Breaker Status To DCS LOGIC



MK5 WIRING CONNECTIONS SIGNAL NAME CORE CARD TERMINAL DESCRIPTION 4CT DTBB 75/76 CUSTOMER TRIP (already connected) CA4_FSNL DTBB 07/08 TRIP GEN BREAKER FROM DCS CA70_RB DTBB 09/10 LOAD RUNBACK FROM DCS S3 DTBD 76/77 COMPLETE SEQUENCE TO DCS S52GX1 DTBD 79/80 GEN BREAKER STATUS TO DCS TTXM_OUT CTBA 01/02 EXHAUST TEMPERATURE TO DCS TNH_RPM_OUT CTBA 03/04 TURBINE SPEED IN RPM TO DCS RECALIBRATIONS REQUIRED Recalibration of the following devices will be required following the conversion to combined cycle mode and base load exhaust pressure data is available to Sulzer/TTS: 63EA-1 : Current device summary setting of 16 InH2O. (New Setting Required) 63ET-1 : Current device summary setting of 20 InH2O. (New Setting Required) 63ET-2 : Current device summary setting of 20 InH2O. (New Setting Required)



Standard HRSG High Temperature Protection

UnitAtHighLoadInPremix

BoilerRunback(CA70_RB)

NoYes

TransferToPPM

PilotedPremixTransferComplete

ReduceLoadToTTXM

10-1435 sulzer-guaracachi santacruzbolivia tech report

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