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 Title slide [from Title Slide master] The title slide is available as a Title Master and the background and graphic elements are fixed. Text is editable for the slide heading and presentation details but the small compliance text exists in editable form only on the Title Master itself. This type area should be used only for the purposes of compliance text and should not be replaced by other content. Font, type size and colours are fixed for the Title Master style and should not be modified. Footer details Footer detail appear in the bottom-left corner of the slide and appear in fixed positions and order. Editing of the Footer details is done by accessing ‘Header and Footer’ under the ‘View’ menu in PowerPoint®. © Invensys 00/00/00 Invensys proprietary & confidential

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 Text slide, with title and body text [from Slide Master] This slide exists as a Slide Master and all type specifications and graphic elements are fixed. Simply type into the prompt boxes. The layout is set as a Title Box and Text Box – within the Text Box there are five levels of type: Level 1 – Body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 2 – Bulleted body text set in Verdana Regular (18pt on 24pt linefeed) with ‘0.5 line’ space below each paragraph. Level 3 – Bulleted body text (using a horizontal dash) set in Verdana Regular (16pt on 20pt linefeed) with ‘0.5 line’ space below each paragraph. Level 4 – Bulleted body text set in Verdana Regular (15pt on 18pt linefeed) with ‘0.5 line’ space below each paragraph. Level 5 – Bulleted body text (using a horizontal dash) set in Verdana Regular (14pt on 17pt linefeed) with ‘0.5 line’ space below each paragraph. Within standard body text, subheads are set in Verdana Bold at the same size as the body text. Advancing through the text levels To advance to each text level from the previous one you can use the ‘Increase Indent’ and ‘Decrease Indent’ buttons on the ‘Formatting’ toolbar in PowerPoint®. While the text position is fixed, the text box will grow as you enter further content in the slide – therefore, care should be taken to keep within the present text box margins.

GenOn Energy Chalk Point Station

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) Bold subheadlines [from Slide Master] Subheadlines may be applied in Verdana Bold. These should be the same size as the body text to which they apply and should not use highlight colours or any different styling or type attributes.

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 Numbered text slide [from Slide Master] Numbering can be activated from the button on ‘Formatting’ toolbar in PowerPoint®. The numbering style which you get as a default may not always be the correct format or colour; all numbering should be coloured Green [from the colour palette] and in Verdana Regular.

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 Numbered text slide [from Slide Master] Numbering can be activated from the button on ‘Formatting’ toolbar in PowerPoint®. The numbering style which you get as a default may not always be the correct format or colour; all numbering should be coloured Green [from the colour palette] and in Verdana Regular.

Siemens Control Panel Numbered text slide [from Slide Master] Numbering can be activated from the button on ‘Formatting’ toolbar in PowerPoint®. The numbering style which you get as a default may not always be the correct format or colour; all numbering should be coloured Green [from the colour palette] and in Verdana Regular.

Control panel

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

Siemens Control Modules

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 Numbered text slide [from Slide Master] Numbering can be activated from the button on ‘Formatting’ toolbar in PowerPoint®. The numbering style which you get as a default may not always be the correct format or colour; all numbering should be coloured Green [from the colour palette] and in Verdana Regular.

Siemens Configuration Code

Siemens Configuration Diagram

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 Numbered text slide [from Slide Master] Numbering can be activated from the button on ‘Formatting’ toolbar in PowerPoint®. The numbering style which you get as a default may not always be the correct format or colour; all numbering should be coloured Green [from the colour palette] and in Verdana Regular.

Remote Control Room - Before

Remote Control Room - After

Control Rooms - After Local Remote

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 Numbered text slide [from Slide Master] Numbering can be activated from the button on ‘Formatting’ toolbar in PowerPoint®. The numbering style which you get as a default may not always be the correct format or colour; all numbering should be coloured Green [from the colour palette] and in Verdana Regular.

Control Racks Before After

After I/O Wiring Before

Configuration - After

Graphic- Main Menu

Graphic - CT Overview

Graphic - Startup Page

Graphic - Permissive Overlay

Graphic - Fuel Gas Control

Graphic - Breakers

Questions? Questions? Questions?