Presentation is loading. Please wait.

Presentation is loading. Please wait.

© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys.

Similar presentations


Presentation on theme: "© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys."— Presentation transcript:

1 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. © Invensys 00/00/00Invensys proprietary & confidentialSlide 1 Non-OEM Gas Turbine Controls Replacement Session Name: Turbomachinery Integrated Solutions & Control System Replacement for Siemens Gas Turbines Session ID #: PBTR113 Tanesua Williams Nov/09/2011

2 Slide 2 Plant Overview GenOn Energy Chalk Point Station Located in Aquasco, MD 2,400 MW - Largest power station in MD Coal, Oil and Natural Gas Generation 4 Steam Units 7 Combustion Turbines

3 Slide 3 GenOn Energy Chalk Point Station

4 Slide 4 Unit Overview CT5 & CT6 Installed 1991 Siemens KWU V84.2 Dual fuel – oil and gas 125 MW Peaker Siemens Teleperm ME Controls – last 2 in the US 1800 I/O (900 per unit)

5 Slide 5 Project Overview The case for replacement Forced outages Card failures – averaging 5/yr Troubleshooting – difficult and tedious Support – extremely limited, no OEM support, one person with ME experience Parts – cards sent to South Africa for repair and testing, limited to none spare parts

6 Slide 6 Challenges Non-OEM Control System – ambitious task for Invensys, little in- house knowledge, extended FAT Learning curve – Invensys engineers had to get up to speed on Siemens code and configuration and German translations Different German standards – current interfaces not standard, different grounding methodology KKS structure – non-standard tag identification (MBN21AA001) Custom, proprietary hardware and software – all custom code and specialized hardware

7 Slide 7 Siemens Control Panel

8 Slide 8 Control panel

9 Slide 9 Challenges I/O modules – each module had individual application program in addition to the main program Dual Fuel System – unit can operate on oil or gas, gas also used for pilot valve Ball valve sequencing – ball valve sequencing key to ensuring no trips during startup and fuel and burner swapping Pilot gas stabilization – required during oil startup Fuel swapping – unit must swap from oil to gas and vice-versa while online and without tripping Burner switching – unit must flawlessly swap from diffusion to premix while online

10 Slide 10 Siemens Control Modules

11 Slide 11 Challenges Code extraction – assembler code, 16,000 lines of code, could not be extracted – engineer had to review line by line to ensure all items were accounted for in new system Wire wrap terminations – 24 gauge, easily broken, special tool required Documentation – configuration docs and drawings not up-to-date and very tedious to follow. Tracing single item required up to 4 different documents Iskamatic (governor) – little to no in-house or OEM knowledge and poor documentation

12 Slide 12 Siemens Configuration Code

13 Slide 13 Siemens Configuration Diagram

14 Slide 14 Results Triconex TMR TS3000 with TriStation 1131 Software Wonderware InTouch HMI Improved reliability – unit startup, fuel swaps Increased availability – reduction in forced outages Modernized control room – updated furniture and control environment, increased employee morale Maintainable system – current, updated system with trained operators

15 Slide 15 Remote Control Room - Before

16 Slide 16 Remote Control Room - After

17 Slide 17 Control Rooms - After Local Remote

18 Slide 18 Results Available support and parts – readily available parts and service Improved diagnostic capability – I/O status screens, controller info User friendly interface – operator screens, better navigation Improved troubleshooting capability – emulator, control sheets Documentation – updated and current, simplified Data collection – trending, historian Alarm management – first out, history

19 Slide 19 Control Racks Before After

20 Slide 20 I/O Wiring Before After

21 Slide 21 Configuration - After

22 Slide 22 Graphic- Main Menu

23 Slide 23 Graphic - CT Overview

24 Slide 24 Graphic - Startup Page

25 Slide 25 Graphic - Permissive Overlay

26 Slide 26 Graphic - Fuel Gas Control

27 Slide 27 Graphic - Breakers

28 Slide 28 Questions? Questions? Questions?


Download ppt "© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys."

Similar presentations


Ads by Google