IndustrialIT for Power Generation

PROCONTROL P Enhanced with IndustrialIT

Content Introduction....................................3 IdustrialIT for Plant Management....4 Plant Automation............................5 Turbine Automation......................17 Boiler Protection...........................18

2 ABB

Introduction PROCONTROL P: Reaches new levels of performance with IndustrialIT

Within ABB’s new family of integrated software and hardware solutions – collectively known as IndustrialIT – the PROCONTROL P Enterprise Management and Power Plant Control System positions customers to optimize process, plant and enterprise operations. While reaping the benefits of the innovative, enhanced IndustrialIT strategy, customers will retain both the process security and the value of their new or existing PROCONTROL P system.

PROCONTROL P enhances the real-time sharing of knowledge between related but divergent enterprise operations. Fully equipped with an integrated set of decision-making tools, IndustrialIT makes it possible for real-time information to be shared – and its value compounded – throughout an organization. The result is better and faster decisions that optimize company assets, whether people, raw material, process or infrastructure. An efficient Asset Management based on IndustrialIT is now the success factor for the modern utility.

Open Architecture for Seamless Integration

IndustrialIT applications are designed to be used as stand-alone or integrated solutions, enabling the flexibility to implement the required functions today and the agility to add on as

needs evolve. ABB’s diligent use of open standards simplifies the task of interfacing with existing automation and information systems, while the proven PROCONTROL P progression ensures an additional layer of established investment protection.

The Evolution Continues…

IndustrialIT is the latest installment on a 20-year commitment ABB has made to its DCS users. The company’s pledge of Evolution through Enhancement ensures that future advances in system technologies will not compromise the customer’s current investments.

A Global Leader Today, Evolution through Enhancement has expanded to include the latest products and services from the world’s largest automation supplier; including instrumentation, analytical devices, meters, robotics, drives, motors, mach-ines, manufacturing execution systems, and control products and systems. Backed by common IndustrialIT technology and industry specific expertise, ABB’s automation portfolio provides the seamless link between process and business management to deliver knowledge-based solutions. PROCONTROL P is a digital process control system, which combines innovation and broad functionality with established operational reliability. Development of the PROCONTROL P power plant control system is ongoing with the aim of further improvement of:

Cost-effectiveness,

Functionality,

Quality.

ABB 3

IndustrialIT for Plant Management Deregulation and liberalization has turned the power generation sector into a competitive market. In order to succeed, power producers have to explore all means for generating and marketing energy that is inexpensive, environmentally sound and clean. Prerequisite for maximum cost-efficiency is the optimization of the entire power generation portfolio (equipment operation, fuels, etc.).

The focus is on:

Optimum plant efficiency,

Cost transparency,

Optimum plant operation,

Minimum downtimes,

Improved maintenance.

These goals are achieved by employing up-to-date information management in order to collect and analyze the status and condition data of the plant and all relevant business data. Examples are OptimizeIT Unit Commitment and AdviseIT Plant Performance. OptimizeIT Unit Commitment optimizes purchase, production and sales for a fleet of power plants. AdviseIT Plant Performance calculates and improves the efficiency of power plant unit components on-line.

The solution is IndustrialIT for Plant Management IndustrialIT for Plant Management helps operators to take the right decisions at the right time. It assists power plant staffs and plant managers in operating their facility in the most cost-effective manner.

Increased efficiency This optimization software calculates the efficiency levels for boilers, steam and gas turbines; it computes the balance of the plant,

the controllable operating parameters and the optimal mode of operation.

More information

IndustrialIT for Plant Management delivers all relevant process information, data on costs, and the measured values. The process information management feature collects the data from the interfaced control systems and applications. The data are then graphically represented on terminals at the engineer and management levels.

Improved maintenance Modern maintenance solutions allow to optimize the down time, the use of spare parts, purchasing as well as the usage of mainte- nance staff. The condition or risk based maintenance allows to reduce maintenance costs considerably. All these concepts are based on process information which can be ensured by the good integration of plant maintenance and plant management.

Best possible utilization of the production portfolio

IndustrialIT for Plant Management computes the best possible production scenario with the aid of simulation and optimization routines. The system offers assistance regarding make-or-buy decisions, how to market reserve capacities and for contract management.

4 ABB

ABB

5

Enhanced availability

IndustrialIT for Plant Management monitors the lifetime consumption of critical components by detecting weak points early. The IndustrialIT for Plant Management program packages support routine maintenance and provide valuable information on how to promote low-stress start-up and shut-down procedures. In addition the lifetime data can be displayed for all major components.

IndustrialIT for Plant Management is integrated with the PROCONTROL system. This permits fast and simple extension of the proven PROCONTROL functionality with a full range of plant management functions, from process information management and process optimization to maintenance and service assistance.

The functionality of POS30 is characterized by:

Efficient plant control and data access from any POS30 display station.

Provision of a complete set of displays which are necessary for efficient control as e.g. mimics, trends, sequence of events and characteristics.

Access to the PROCONTROL P bus means access to all the control system data of a power plant. Most of these data can provide important information for the operational management of the plant, either directly or after processing. Such management systems include for example maintenance services, materials management, accounting and plant book-keeping functions.

Support of the operator in case of abnormal plant conditions by fast access to relevant displays and efficient navigation among displays.

High resolution graphics and windowing, support of workplace concepts, multi-screening, mouse as preferred pointing device. Plant Automation Consistent and uniform color scheme,

adaptable by authorized users. Process Operator Station POS30 Basic process and plant management

functions: data recording, calculations, counting of operating time, switch cycles, impulses and quantities and a broad range of reporting facilities.

Innovative human-system-interface The POS30 operator station available for PROCONTROL P has proven to be the ideal tool for controlling, supervising, monitoring, analyzing and optimizing the power plant process. It is a consistent and uniform user interface for the whole plant, even if the plant is subdivided into different locations.

System security ensured by personal user accounts with password profiles.

System diagnosis with summary status information. Scalable system performance and flexible

hardware and network expandability enables POS30 installations to grow up from the smallest single user configuration to the largest enterprise-wide full scope system to keep up with the user's growth requirements.

Client/ Server architecture based on industrial PCs, running Linux, a powerful operating system.

The POS30 system consists of three main components:

Display of trends to give warning of potentially critical situations.

1. OMS: The Operation & Monitoring Services. OMS is the basic component of POS30. It provides the functionality for all process control requirements.

All these features enable even complex power plants to be operated by a minimum of staff. Important in this respect are well designed operator positions which present the right information at the right time and provide the corresponding means of intervention.

2. RCR: The Recording, Calculation & Reporting Services. RCR is an option covering the process and plant management functionality.

A hierarchy of displays includes the plant overview, area overviews, function group displays and detail displays. All these displays develop the operator's ability to recognize patterns so that the causes of sudden events are quickly identified.

3. XTC: The XTC Data Interface provides facilities to integrate 3rd party DCS and PLC systems (e.g. via OPC), to com-municate with plant management & optimisation systems and to enable multifaceted remote access features. The mimics are the main instruments of control.

They present up-to-date process information and the process itself in a form familiar to the operator. The mimics are fully configurable and include many graphic elements and symbols, which give a precise and easily assimilated picture of the plant. To illustrate the current status of the process, the displays make use of dynamic color-coded symbols, trends, bar charts and numeric values.

POS30 OMS Operation & Monitoring Services The following principles were observed when designing OMS:

Supervision of the process using overview displays,

Control and supervision of the current status in mimic diagrams with on-line confirmation of any actions executed,

Various views of a sub-process are supported by supplementary displays which are available by pressing a key. Fast homing-in on currently critical areas,

Context-related presentation of supplemen-tary information,

6 ABB

Curve displays can show up to six trends at a high resolution in relation to time. Individual curves can be switched on and off. The time scale display is infinitely variable and permits uninterrupted surveil-lance of selected parameters. A ruler can be moved to any location to "measure" and translate any point of a curve into a numerical value.

Profile displays are groups of measurements of the same type of variable e.g. boiler temperatures. They show the deviations of a given variable compared to the others and enable irregularities to be quickly detected.

The sequence-of-events (SOE) display lists of all recorded events in chronological order. This includes disturbance signals, changes of status and operator actions. The list sup-ports straightforward analysis of the causes of particular incidences. The analysis proce-dure can be accelerated by a series of se-lection filters which can be activated to sup-press irrelevant events.

Characteristic displays show the current operating points of important plant components together with their efficiency and operating limits. They are used for determining permissible or optimum operating modes.

Common to all the displays is a uniform color scheme. But authorized users can modify any color. This is done by simply clicking on any object with the desired color and changing it. Thus it is possible to select any background color and adjust the colors of the various objects.

Process control and supervision Process operation: Every megawatt at your fingertips

Pointing and clicking on any dynamic process component in a display, from the drive level to the highest control level opens a control window. In the center of the window, the control elements for the components appear. Commands are given with the aid of simulated

ABB 7

buttons and slides on the screen. The OK but-ton replaces the conventional release function. Top and bottom sections are common to all control windows and simplify acknowledge-ment, viewing loop details and cross-selecting related displays. Every control window can be moved to any location on the screen and opened from any kind of display. Up to four control windows can be open at the same time and operations in them performed parallel.

Buttons for navigating around in the display hierarchy, separately for standard displays and mimics, enabling the operator to switch quickly from the higher-level plant overview to a mimic or detail display.

Buttons for paging through the hierarchy which enable the operator to go on an "inspection tour" through the plant at any desired level

"Last display" and "Last mimic" buttons enable the operator to back-track through the last 10 displays.

Selection from display lists and selection from a field of user-configurable softkeys.

The softkeys in the footer are configured by assigning current displays or by accepting predefined monitor and window combina-tions.

Assignment of up to 8 displays is possible with one keystroke providing just the right combination of displays for certain opera-tions, e.g. start-ups.

Navigation: As a further aid to navigation through the

displays, it is possible to allocate certain displays (e.g. curves) either temporarily or permanently to a specific VDU or window, i.e. a VDU or window can be reserved for a particular mimic so that it is always instantly available.

The compass in the power plant

Fast navigation around the plant displays - especially in critical situations - can significantly influence power plant efficiency and availability. This applies to normal operation but is especially true for disturbed operation. The process operator station provides a number of standard and configurable options for fast navigation:

POS30 RCR Recording, Calculation & Reporting Process supervision: The shift supervisor's tool box

Process data are saved, documented and evaluated for a number of purposes:

Detection of deviations and initiation of corrective action early on

Analysis of the causes of unexpected events

Documentation of plant status for the authorities or plant management systems, etc.,

8 ABB

Provision of balance reports for selected process values, e.g. for verification or commercial purposes.

Disturbance analysis makes full use of all this data storages. This arrangement provides for flexible evaluation of faults, because the range of signals is extensive and there is basically no limit on the period of time. These functions are based on several cyclic or

event-oriented history archives. The corre-sponding data are processed by arithmetic modules, or different kinds of reports are generated from them. A powerful ancillary system which is capable of managing all the information generated throughout the entire power plant is optionally available, where a need exists, for more comprehensive analysis, extensive documentation or adaptation to specific plant conditions.

RCR Reporting: The process curriculum vitae

RCR Recording Histories and archiving: Resources for the future

The OMS component of the process operator station has two buffers for short-term and for medium-term recording of analog variables and one buffer for process events.

Standard reports are available for listing such process data as: The short-term buffer for analog variables has

sufficient capacity for one day at a high resolution (1 second). The medium-term buffer can store analog variables for eight days at a condensed resolution. Both buffers record the mean, maximum and minimum values, are available on-line and can be analyzed using the curve display.

Operating balance reports,

Instantaneous values,

Operating hours,

Switching cycles.

The optional long-term archive (RCR Recording) only records changes of analog, counter and binary values. This enables an overall resolution of less than a second for analog values, combined with a relatively high data compression. At first this data is stored on internal hard disks or on the disks of a NAS server (NAS = network attached storage). In both cases RAID technology is supported.

All reports can be conveniently configured on-line and interactively with drag & drop support.

Report generation and printing can be triggered either manually on request or cyclically. Once a report has been generated, it remains on the hard disk from which it can be transferred for archiving.

Reports are generated in HTML. Hence all reports can be viewed on the screen and printed with standard web browsers (e.g. MS Internet Explorer).As each report is based on a user-definable template layout,

For archiving purposes, data can be transferred to magneto-optical disk, CD-R(W) or DVD-R(W) so that they are available for analysis and viewing later on.

ABB 9

custom fonts, colors, arrangement of tables, integration of graphics may be applied easily with any HTML layout editor like MS Frontpage.

Multi-purpose man-machine interface: The POS30 Process Operator Station The POS30 is equipped with an XTC communication interface and supports the following system features:

Open system architecture, suitable for all types of data communication and third-party system interfacing: plant management systems, process information systems, maintenance systems, SAP, any type of user-defined or purchased application, interactive input/ output features.

Homogeneous and consistent hardware and operating system platform for operator station and XTC communication interface.

Homogeneous and consistent engineering of operator station and communication interface. RCR Reporting includes an integrated

automatic data export of generated reports to other applications e.g. Microsoft Excel. Access to all the process and historical data

of the plant, high level of performance, no restrictions with regard to bill of quantities or dynamics.

To complement the above mentioned tabular report style, any report can be displayed additionally as a graph with user adjustable scaling of y-axis and time resolution (from minutes to years), detailed signal legend and up to four rulers. The standard graph type has time on x-axis and values on y-axis but graphs with on signal on x-axis and another on y-axis are feasible.

Operating modes: intermittent/event- oriented, cyclic, continuous.

Access even to preprocessed and archived data (integration data, averages, counter values, computed values).

Delivery of data in conditioned form (physical values, status information), independent of control system specifications.

The following reports are also available as options for special demands:

Options for direct interfacing of third-party systems (including process operation).

Measured-value-sequence report: The measured-value-sequence report lists a predefined number of analog variables over a given period. This is especially useful for examining transitory operating procedures, e.g. the turbine start-up procedure. It is available for all analogs, binarys and computed values.

Network interfacing, via TCP/IP, with LAN and/or WAN (modem, ISDN).

Optimized features for remote and advanced services by means of consistent application of Internet technology, such as browsers, HTML and HTTP

Plant status report: The plant status report can be prepared for all the variables or for disturbed variables only. Since it reflects the current status of the plant, it is frequently used when handing the plant over to the next shift.

Providing for security of investments through application of industrial standards, such as OPC, OLE/Actve/DCOM and TCP/IP.

10 ABB

POS30 OPC Client Remote Access OPC means OLE for Process Control and is an open standard for the communication between PLC and DCS systems on the one hand side and software applications (meanly process operator stations) on the other – even if the control system and the operator station are products – from different vendors.

POS30 supports many “Remote Access Functions” using internet technology. The main features are: Remote monitoring of live and historical

process data,

Remote report generation, displaying and printing,

Within the following examples the POS30 OPC client software provides the acquisition of data from PROFIBUS, connected via a PROFIBUS OPC server. Even process operation from POS30 into e.g. PLC systems connected to the PROFIBUS is possible.

Remote analysis and diagnosis of POS30 (hardware, operating system and applica-tion software),

Remote analysis and diagnosis of the PROCONTROL system,

Message forwarding in case of disturbances (E-mail and SMS).

Process data derived from OPC signal tags may be used within the POS30 system for all POS30 functions like standard displays, mimics, trend curves or reports. From the operators point of view, the source of information (OPC or PROCONTROL) is trans-parent, i.e. operators have a homogeneous user interface to all process information independent from data origins and interface types.

System Configuration The following configuration shows the system architecture of interfacing PROFIBUS to a POS30 system with OPC.

If necessary, this configuration can be provided with redundant coupling PCs.

ABB 11

Tag List The major design issues for all these remote access functions are: The Tag List provides access to on-line data

using predefined tag lists. It displays process data in tabular form organized in list groups.

One window to the whole process,

Support for integration of 3rd party DCS/PLC types,

Web browser enabled, ease of handling,

Corporation-wide remote access,

Appropriate system security,

Support for thin and mobile clients,

No client installation/ administration,

Simple WYSIWYG configuration (e.g. Fro-ntPage 2000TM),

Based on industry standards.

Remote Access Applications

Tag Report The Tag Report generates and displays on-line and historical process data based on pre-defined HTML report templates.

Tag Display The Tag Display updates process information dynamically. It uses Java applets that can be overlaid with graphics to create “HTML mimics”. The applets can be tailored with parameters to change color, format, etc. Standard HTML editors like MS Frontpage can be used to create the pages.

Tag Browser The Tag Browser provides “instant access” to on-line data. It browses the complete hierarchy of the POS30 server and displays all properties of the selected process items. History Browser The History Browser displays historical data

dynamically. Like in the Tag Display, Java applets are used to create the graphs.

12 ABB

I&C Components I/O modules have their own microprocessors which makes signal acquisition and conditioning more efficient.

Stations: All-rounder or specialist

A station accommodates the instrumentation and control modules (I&C) and the coupling modules for man/ machine interface (MMI) and external systems (e.g. programmable logic controllers, process control systems etc.). The station bus coupler connects the station to the remote bus. The connection to the remote bus is optional and the station can operate in a stand-alone mode.

Unrestricted availability of all measured process variables in real-time.

All data transferred within a station are also available on the remote bus for other units in real-time. Conversely, every station has access to all the data on the remote bus. This principle of all data being universally available ensures absolute flexibility with regard to modifications and system expansion. System maintenance is also simpler.

The independent features of all units and modules permit that they can be distributed between different stations to suit the requirements and possibilities on site.

Perfectly simple: In duplicate PROCONTROL P needs basically only two types of modules to perform all the signal conditioning and binary and analog control tasks - the universal input module and the binary and analog control module . These two modules alone cover 80% of all power plant control functions. The result is a control system with a clear structure, lower costs for stocking spares and simpler maintenance. The main features of a station:

Modular structure with little basic equipment making the system scalable, from the smallest control task to control systems for large-sized plants.

The programmable universal input module includes many features which were simply not available before. All types of transmitters used in power plants can be connected to it. These include for example analog transmitters with an impressed current in the range of 4-20 mA and binary transmitters with integrated NAMUR initiators (DIN 19234).

The control modules process the information independently (multiprocessor system). Heart of the latest developments like the module 83SR52 is a 32bit MC68340 processor. The input module diagnoses the status of each

transmitter, e.g. to detect loss of voltage, short circuit to ground, or wire breaks in process and transmitter wiring. The results of the diagnosis are transferred together with the value of the measured variable.

Central units are not required to perform control system tasks.

ABB 13

Standard interfaces: For each measured variable, the input module can monitor up to four limit values. The permis-sible limits of a variable are therefore monitored where they should be, as part of the signal conditioning and preprocessing function.

Milestones on the road to open communication Interfaces are available for connecting to other control systems and automation devices.

The input module accurately linearizes signals from non-linear transmitters such as thermo-couples. The values of the measured variables and the type of transmitter can be freely programmed on-line for every input signal.

Interfaces are needed wherever different system processes such as programmable logic controllers (PLCs), process control systems, coupling PCs and modems using different interfaces and communication protocols are installed in a power plant. The programmable universal controller is used

for all binary and analog control functions. The programming determines whether the controller has to control a drive, a function group, a discrete regulation task or a complex processing function.

As a consequence of having to couple many third-party systems to the PROCONTROL P bus over the years, a whole range of interfaces covering a wide range of requirements is available.

Data Transfer The data transfer system: Open to ail suggestions Stations are connected to the remote bus with no reactive effects. The station bus and the re-mote bus form a single homogeneous commu-nication system and all process signal changes are available in real-time on the station bus for every station. This unique feature of the system enables related functions such as signal acqui-sition, signal conditioning and binary and ana-log control to be either located together in one station (stand-alone system) or distributed be-tween different stations (according to control functions). Therefore there are no restrictions on the location of modules and any free slot can be used. This makes PROCONTROL P, amongst other things, especially suitable for refurbishing existing power plants.

Subsequent expansion of existing control systems can be achieved simply without having to shut the system down and without encountering problems with interaction between modules.

14 ABB

Remote bus PROCONTROL EDS is the engineering, documentation and service system for the PROCONTROL P power plant control system. It improves the engineering, commissioning and maintenance efficiency.

The high-speed remote bus is based on the FDDI (Fiber Distributed Data Interface) token ring system according to ISO 9314. It is con-nected to the station buses via remote bus coupling modules. Optical fiber cables are used for the actual connections. These are firstly in-sensitive to electromagnetic interference and secondly are suitable for maximum distances of 2000 m between stations, at a data transfer rate of 100 Mbits/s. Maximum network sizes of up to 100 km can thus be achieved.

PROCONTROL EDS: More than just function block programming The engineering, documentation and service system PROCONTROL EDS is a tool for both internal and peripheral control components. It supports the engineering, commissioning and optimization of control system functions. Since it is directly connected to the PROCONTROL P bus, EDS has access to all the modules of the inner control system throughout the plant. A network links EDS to the process operator station.

The FDDI network is in the form of a double ring. The remote bus does not require any common central components and is therefore capable of restructuring the system and main-taining communication in the event of a fault such as the interruption of one of the cables.

The main tasks performed by EDS are: In this way it fulfils the highest demands with respect to availability.

Data entry for the input and mainte-nance of measurement and drive data,

Station bus Generating and editing function charts for

I&C functions, The station bus is confined to a station and links the I/O and processing modules to the system. It comprises backplane p.c.b.s on all the racks, which are connected together.

Allocation of hardware (assignment of func-tions) and downloading of programs,

Debugging of function programs, Engineering, documentation and service for power plants Printing of function charts as necessary.

EDS provides function-oriented as well as implementation views. The power plant designation system e.g. the German KKS (tag name) is used to identify engineering items; any addresses or other specific control system data are not required. A function is selected by its designation and displayed graphically as a function chart on the screen. The user executes any changes directly in the function chart.

Many tasks - one system: Engineering, documentation and service

The function editor knows all the PROCONTROL P function blocks and the rules for connecting them. When generating a function using EDS, the user selects a function block and connects it to other function blocks by clicking on them with the mouse!

ABB 15

The computer then automatically arranges function blocks and their interconnections in the chart in relation to the syntax rules.

Signal error.

Provision is also made for overwriting signals with values to be simulated for test purposes. All settings, limits and controller parameters in a function chart can be selected and changed if necessary.

The data used by the function generator are also needed to program the control modules and to configure the communication systems. This principle ensures absolute consistency between the actual programming of the control system, the configuration of the communication systems and the associated documentation.

Control system diagnosis: Down to the smallest detail The control diagnostic system (CDS) makes use of the special PROCONTROL P features, for example, every I/O modules has its own mi-croprocessor and is therefore independent and able to monitor and diagnose itself. These func-tions are active as soon as a module is inserted into its rack. Also all process data are available via the bus to all other system modules. Thus without having to be configured, CDS is able to recognize all the modules in the system and display them graphically together with their cur-rent statuses.

EDS automatically updates any other function charts and the connections to them which may be concerned. All cross-references are there-fore always up-to-date and it is possible to navigate horizontally through the function charts by clicking on inputs and outputs.

The same applies when making modifications, i.e. EDS automatically updates the other func-tion charts. Wrong connections are detected and rejected immediately an attempt is made to enter them. Every I/O module communicates its status data,

type and location. From this information, CDS generates the control system graphically on the screen and shows all the cabinets. Cabinets can be individually identified and their states seen from their colors. Clicking on a cabinet "opens" its door and shows the modules in their racks as in reality. Clicking a second time dis-plays the current contents of the register in a module. As soon as a failure occurs CDS guides the user by highlighting the cabinet, module and register concerned and by dis-playing a description of the cause. CDS also provides an on-line recommendation for correc-tive action. CDS includes a report function for analyzing control system and process distur-bance such as the crossing of a limit value. Recorded data can be filtered for a period of time, components and type of disturbances.

On-line testing in function charts: Service made easy Functions are commissioned with the aid of the debugger. The desired function is called by its tag name (e.g. KKS) upon which it appears on the screen as a function chart. It can be selected from the implementation-oriented view (cabinet, rack, modules) or from the function-oriented view showing the functions in their hierarchical relationship.

If the user wishes to observe the dynamic behavior of a signal, he simply clicks on it in the function chart. Because of the direct connection to the PROCONTROL P bus, EDS displays the values of the signals on-line in the function chart. It is not necessary to specify measuring points.

The following supplementary data can be displayed in the function charts:

Logical "0" or "1" for binary signals,

Percentages for analog variables,

Physical units for measurements,

16

ABB

CDS' clear graphic displays enable a compre-hensive diagnosis down to the transmitter level without having to be specially configured. It is thus a valuable instrument for efficiently diag-nosing and correcting disturbances.

Highly adaptable standard modules enable a wide range of applications to be covered using standard, well-tried configurations. For example to raise the efficiency of power plants, it is becoming frequent practice to tap off a part of the steam between IP and LP turbines for district heating. The associated district heating controller can be implemented using TURBOTURN and as an extension to TURBOTROL.

Turbine Automation

Turbine control system: One of the families The turbine control system comprises PROCONTROL P programmable logic components and includes functions for:

Signal conditioning,

Protection,

Binary control,

Analog control,

Monitoring.

The TURBOMAX system is for monitoring the thermal status of turbine parts while starting and during load changes ("load reserve computer"). TURBOMAX optimizes turbine control time with a minimum of stress on the module.

Each of these functions has a clearly defined task while running up or shutting down the turbine and while operating in the load control mode.

The measured variables are preprocessed in the electronic input circuits of the binary and analog control modules. PROCONTROL P components have also proved reliable for turbine protection.

Gas Turbine Control The EGATROL System is a taylor made solution for the gas turbine process which consists of PROCONTROL P components.

As in the case with the other parts of the power plant control system, the turbine control system has a hierarchical structure and a functionally distributed layout. Control of the turbine is fully automatic.

The design of EGATROL has been trimmed to the technical requirements of the gas turbine process. The turbine control system is designed to fulfill the requirements for control of the gas turbine at all operating conditions.

Steam Turbine Control Analog Controls -The task of the EGATROL control system is to control continuously process variables according to set point values that must be fulfilled for the startup and shutdown of the gas turbine as well as for the steady state operation (including load variations) during which static and dynamic limitation come into effect.

The turbine regulator part of the steam turbine control system is designed to control small to medium-sized turbines mainly for industrial applications (TURBOTURN) as well as the large reheater turbines used by power utilities (TURBOTROL).

ABB 17

The static limits are determined by the permissible loads and the dynamic limits additionally by the temperature margins.

Protection - Based on in-depth failure mode analyses the various criteria related to protec-tion have been categorized into different classes depending on the magnitude of dam-age that can occur when the parameter ex-ceeds permissible limits. Each causal factor is designed to initiate different actions e.g. alarm, load shedding (PLS) with or without delay, opening of generator breaker (PLST), or trip-ping the gas turbine (TRIP). The protection system is designed in a fail-safe manner.

The analog control for the gas turbine consists of the following main functions:

Startup/ Shutdown control,

Frequency/ Load control,

Temperature control,

Guide vane position control, The protection logic is processed in a 2 out of 3 configuration in each of the three channels. The outputs are connected to the hydraulic protec-tion circuit. The system operates in a de-energized to trip mode to increase the safety.

Fuel distribution control,

Gas/ Fuel Oil division.

Binary Controls - The operation of the gas turbine is a fully automated process with the various auxiliaries of the turbine being auto-matically switched in and out of operation in a sequential manner. There is no operator inter-vention required except for the selection of the fuel and the setting of the load before the se-quence start.

Boiler Protection

PROCONTROL PF protection system: Programmed Iogic safety

The gas turbine process is divided into the following main function groups which is implemented in PROCONTROL DCS seamlessly:

The purpose of the protection system is to re-liably prevent operating situations which repre-sent a hazard for persons or plant. Safety-ori-ented control systems have the task of switching the process to a safe state before a potentially dangerous situation can become critical. At the same time safety-oriented control technology ensures a high level of operational availability of the facility in the best interest of the plant user.

Startup / Shutdown Sequencer,

Lube Oil,

Fuel Gas,

Fuel Oil,

Power Oil, PROCONTROL PF is a three-channel stored-program protection system allowing the imple-mentation of safety-oriented applications.

Starting Device,

Turning Gear,

Excitation, It includes standard test functions for periodi-cally testing all the protection system compo-nents such as:

Synchronization.

Input signals, Input modules, Output signals,

Tripping circuits.

18 ABB

Even during testing, the protection system is in the active state in order to be able to effect emergency trips if need be.

The PROCONTROL FDDI bus provides non-interacting connection of PROCONTROL PF to all the plant control functions. All relevant data for archiving, diagnostics and operation are therefore available throughout the control sys-tem at all times. The use of field-proven mod-ules of identical design requires no additional interfacing efforts and facilitates the diagnostic functions and maintenance activities.

Safety-relevant signals and circuits are gener-ated, processed and tested within the protec-tion system. The test routines for channels test the control functions without interfering with the control activities of the system.

ABB 19

IndustrialIT for Power Generation The Next Way of Thinking

PROCONTROL P, Power Plant Control System enhanced with IndustrialIT Windows NT®, Windows 2000®, EXCEL®, Explorer are registered trademarks of the Microsoft Corporation, USA. SAP R/3 is a registered trademark of the SAP AG. Linux is a registered trademark of Linus Torvalds.

ABB Utilities GmbH P.O. Box 10 03 51 D-68128 Mannheim Kallstadter Straße 1 Hermann-Schoppe-Straße 4 D-68309 Mannheim D-32425 Minden Phone: +49 (0) 621 381-3000 Fax: +49 (0) 621 381-2645 E-Mail: powertech@de.abb.com Internet: www.abb.com

NOTE We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction – in whole or in parts – is forbidden without ABB's prior written consent. Copyright© 2003 ABB All rights reserved

DEU

TD 1

069

02 E

Prin

ted

in G

erm

any

(07.

03.--

300-

PON

L)