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
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© Invensys 00/00/00
Invensys proprietary & confidential

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
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3. GenOn Energy Chalk Point Station

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)
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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
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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
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7. Siemens Control Panel Numbered text slide [from Slide Master]
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8. Control panel

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. Siemens Control Modules

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
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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.

12. Siemens Configuration Code

13. Siemens Configuration Diagram

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
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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.

15. Remote Control Room - Before

16. Remote Control Room - After

17. Control Rooms - After
Local
Remote

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
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.

19. Control Racks
Before
After

20. After
I/O Wiring
Before

21. Configuration - After

22. Graphic- Main Menu

23. Graphic - CT Overview

24. Graphic - Startup Page

25. Graphic - Permissive Overlay

26. Graphic - Fuel Gas Control

27. Graphic - Breakers

28. Questions? Questions? Questions?