TURBOTRONIC 4 CONTROL SYSTEM

Power Generation

CONTROL SYSTEMS

Introduction
Solar's Turbotronic 4 control system is used for sequencing, control, and protection of the gas turbine package, and for providing an extensive range of options for monitoring and plant control. The control system is based on a commercially available programmable controller configured to Solar's requirements. It provides an optimum combination of control and display features, reliability and maintainability, and is configured specifically for the control of turbomachinery and associated equipment. The control system described herein is provided for Power Generation products and includes a number of sensors, transducers, and monitoring devices. Data are collected and sent to the programmable controller for computation and generation of the required control actions and indications. The programmable controller, in conjunction with the video display unit (VDU), permits a wide range of features. These include a variety of advanced software and control options, as well as condition and trend monitoring and supervisory control. The control system provides the operator with necessary information for operation of the equipment. It also offers a variety of communications options for data exchange with the customer's supervisory system.

Contents
Introduction................................................................................................................................................... i Standard Hardware .................................................................................................................................... 1
GENERAL INFORMATION ....................................................................................................................... 1 ONSKID CONTROL CONSOLE................................................................................................................ 1 PROGRAMMABLE CONTROLLER .......................................................................................................... 2 INPUT/OUTPUT MODULES ..................................................................................................................... 3 INTERNAL COMMUNICATION................................................................................................................. 4 POWER SUPPLY SYSTEM ...................................................................................................................... 4 BACKUP SYSTEM .................................................................................................................................... 4 VIBRATION MONITORING SYSTEM....................................................................................................... 5 GOVERNOR.............................................................................................................................................. 5 GENERATOR CONTROL AND PROTECTION........................................................................................ 6 VOLTAGE REGULATION ......................................................................................................................... 7 CONTROL AND PROTECTION................................................................................................................ 7 OPERATOR INTERFACE ......................................................................................................................... 9

Optional Control and Display Features ................................................................................................. 15

ENGINEERING UNITS............................................................................................................................ 15 FIRE DETECTION AND SUPPRESSION SYSTEM ............................................................................... 15 FIELD PROGRAMMING ......................................................................................................................... 15 LANGUAGE............................................................................................................................................. 15 COMMUNICATIONS TURBINE CONTROL TO SUPERVISORY SYSTEM ....................................... 15 VIDEO DISPLAY OPTIONS .................................................................................................................... 18

Appendix A: Hardware ........................................................................................................................... 20

PHYSICAL HARDWARE......................................................................................................................... 20 ELECTRICAL SPECIFICATION.............................................................................................................. 20 ENVIRONMENTAL SPECIFICATION..................................................................................................... 20 RFI/EMI SUSCEPTIBILITY AND EMISSION ..........................................................................................20

Appendix B: Technical Supplement ..................................................................................................... 21

HARDWARE INFORMATION ................................................................................................................. 21 HARDWARE CERTIFICATION ............................................................................................................... 22 AREA CLASSIFICATION ........................................................................................................................ 22 QUALITY ASSURANCE.......................................................................................................................... 22 CONTROL CONSOLE LAYOUT ............................................................................................................. 22

Appendix C: Control System Information ............................................................................................ 24

TURBOTRONIC DEFINITIONS .............................................................................................................. 24 HUMAN MACHINE INTERFACE DESCRIPTIONS ................................................................................ 24 SYSTEM DESCRIPTIONS...................................................................................................................... 24

Caterpillar is a registered trademark of Caterpillar Inc. Solar, Centaur, Titan and Turbotronic are trademarks of Solar Turbines Incorporated. Specifications subject to change without notice. Printed in U.S.A. 2002 Solar Turbines Incorporated. All rights reserved. SPTT-PG/802

ii

Standard Hardware
GENERAL INFORMATION The Turbotronic 4 control system is a highly integrated programmable controller-based control system with a video display unit (VDU) and operator interface panel (Figure 1). The control system consists of several distinct modules: a programmable controller, input/output (I/O) modules (discrete and analog), VDU, relay backup system, control and monitoring software, onskid control console, and the package sensing and control elements. The internal computing capability of the control system may vary by product line, but each control system has the same basic internal components, as depicted in Figure 2. The control system requires a source of 24Vdc nominal power, which is derived from a source of 120-Vdc power supplied by a battery bank with associated battery charger. ONSKID CONTROL CONSOLE The control system is provided in two onskid, NEMA 4 boxes. The control system is designed to operate in a nonhazardous area. The turbine control panel and onskid VDU include all necessary switches and indicators for gas turbine operation.
OPERATOR'S INTERFACE

Figure 1. Typical Control Console

PROGRAMMABLE CONTROLLER

DISPLAY

CONTROLNET LINK

CONTROLNET BRIDGE REDUNDANT MODULE

CONTROLNET LINK FLEX I/O MODULES BACKUP RELAY SHUTDOWN COMBINATION GENERATOR CONTROL MODULE

TURBINE GENERATOR

Figure 2. Typical Package Control System 1

All components within the control console are factory interconnected and wired to the sensors and transmitters. Labels are in English, but can be provided in various other languages (see "Optional Control and Display Features"). PROGRAMMABLE CONTROLLER The heart of the control system is the programmable controller. The programmable controller performs the following functions in conjunction with the input and output signal modules: Sequencing of gas turbine and auxiliaries Control of turbine and driven equipment during start-up, loading, operation and shutdown Protection of turbine from abnormal operating conditions Protection of driven equipment from abnormal operating conditions Response to commands from operator Analog and status outputs for display and monitoring

The programmable controller is programmed in a language called relay ladder logic or in function block diagram programming. Ladder logic format (Figure 3) is quite familiar to most operators and engineering personnel, since it closely emulates the relay logic used in the past. It also includes a variety of computational and file transfer commands useful for data manipulation, calculation, and communication. Using an optional programming terminal, the user can monitor the program online and troubleshoot a problem or make modifications when required (see Programmable Controller Field Programming option). In addition to viewing the ladder logic online, a copy of the ladder files may be printed out. Function block diagram programming (Figure 4) allows control algorithms to be programmed in a graphical format familiar to process control engineers. This format can program a complex algorithm on one page that would take multiple pages of ladder logic to implement. The compact program is easier to read, troubleshoot, and understand.

Figure 3. Ladder Logic Diagram

Figure 4. Function Block Diagram Programming INPUT/OUTPUT MODULES In order to perform many of its functions, the programmable controller must gather physical data. This is accomplished through I/O modules that are provided as discrete (input, output, or both) or analog (input, output, or both). Discrete inputs are typically used for alarms, shutdowns, or status indications and analog inputs are used for scaleable functions. The I/O modules are mounted to terminal base units (Figure 5). Terminal base units have two primary functions. First, when they are connected side to side, the bases serve as a backplane, allowing data to be transferred from the I/O module to the programmable controller via ControlNet 1.5. Second, the terminal base acts as the terminal strip to which the field devices are wired. Data are transferred to and from the I/O module via an adapter module. The adapter serves as a communication hub between each of the attached I/O modules and the programmable controller, providing not only I/O data, but also individual module status and health. In addition, the adapter also serves to power the internal logic for as many as eight I/O modules.

Figure 5.

Typical I/O Module Mounted on a Terminal Base Unit

Discrete Input Modules. Discrete input modules receive signals from on/off devices, such as level switches, pressure switches, push buttons, relays, and protective equipment normally used during sequencing of the gas turbine. Discrete signals can be used for alarms, shutdowns or simply indicators, but are not necessarily displayed. The discrete input modules can have a capacity of up to 16 channels depending on module type. Discrete Output Modules. Discrete output modules are used to drive output devices such as solenoid valves, relays or motor contactors. The discrete output module is capable of having either 8 or 16 channels of output data per module. If dry contacts are required, then a set of interposing relays or a two-amp contact relay output module may be provided at additional cost. Analog Input Modules. Analog input modules accept analog signals and digitize the data for transfer to the programmable controller. Modules can accept either four or eight single-ended inputs, with different channels being used for different types of input. Each channel is individually configured for current or voltage by choosing where the input is connected on the terminal base. Temperature Modules. Temperature modules serve to condition and transfer temperature data from package resistance temperature detectors (RTD), 100-ohm platinum preferred, and thermocouples to the programmable controller. The temperature module has eight input channels. Speed Modules. Speed modules perform highspeed frequency algorithms. The frequency inputs can accept frequencies up to 32,767 Hz. The speed module has two input channels, each of which may accept magnetic pickup signals from 500 mV to 28 Vac peak. Analog Output Modules. Analog output modules are used to send an analog signal, either repeating one of those supplied by the purchaser or used in the basic control or display of the control system. The analog output module is a fourchannel output module. INTERNAL COMMUNICATION Communication between the programmable controller and I/O modules is via ControlNet 1.5 (Figure 2). ControlNet 1.5 is a high speed, deterministic, serial communications link. This can be 4

used with both non-Flex I/O and Flex I/O and can handle communications over distances of up to 1000 m (3300 ft), or more if repeaters are used, at a bus speed of 5.0 megabits per second. This is more than 50 times faster than the widely used Data Highway Plus (DH+) and the Remote I/O systems. The physical layer of ControlNet 1.5 is quad shielded RG-6U coaxial cable, with a passive tap used to make a connection. The most significant features of ControlNet 1.5 are its speed and the fact that it is both deterministic and repeatable. Deterministic is the ability to reliably predict when data will be delivered, and repeatability ensures that transmit times are constant and unaffected by devices connecting to, or leaving, the network. The network update time for a typical turbomachinery control system is around five milliseconds. POWER SUPPLY SYSTEM The power supply system supplies power to the programmable controller, input/output modules, video display unit, and relay backup systems. It consists of independent, voltage converting, dcto-dc isolating power supplies. The system receives 120-Vdc input from the battery system and converts it into a regulated and filtered 28-Vdc power at a maximum of 20 amps. BACKUP SYSTEM The basic control system is equipped with an independent relay backup system that serves to initiate emergency shutdown of the turbomachinery and to control the post-lube cycle. Critical input signals monitored by the backup system include the backup power turbine overspeed monitor, manual emergency stop switches (located at the console and turbine skid), the programmable controller fail watchdog timer, and the fire system relay contacts. When activated by any of the above faults, the relay backup system initiates a safe shutdown of the turbine and driven equipment. The backup control system is a combination of instantaneous and time delay relays. When a failure of the programmable controller occurs, all discrete outputs are automatically switched off. The programmable controller fail relay is re-energized on a fault condition. A fault is initiated either by the internal programmable controller watchdog or by failure of the output module. The programmable controller fail relay contacts are used in the relay backup system to initiate an emergency shutdown, to isolate the driven equipment by transferring block valves or circuit breakers to their safe position, and to sequence operation of the post-lube oil system.

Once a shutdown is initiated by the backup system, operation can only be restored manually by a safety key switch lockout located on the console front panel when all faults have been cleared. This action re-energizes the master control relay and its associated relays and timers are restored to their normal position. VIBRATION MONITORING SYSTEM The vibration monitoring system provides vibration indication and protection for the gas turbine, gearbox, and driven equipment. Depending on the unacceptable vibration level, either a warning is indicated or a turbine shutdown is initiated. The gas turbine vibration monitoring instrumentation consists of a single proximity probe per bearing or two velocity transducers per engine for the Centaur 40 gas turbine. The gearbox is typically instrumented with an accelerometer. The generator is typically instrumented with a velocity transducer per bearing. The proximity probes, accelerometers, and velocity transducers are connected to individual transmitters that provide 4-to-20 mA signals to be read by the turbine package control system. All data available to the programmable controller are also obtainable via serial link for user remote monitoring, diagnostics and trending. Direct access to the raw vibration signals is available via BNC connectors. GOVERNOR The "governor system" consists of various hardware and systems integrated together to provide the governor function. The governor is a speed, load and temperature control system whose dominant signal depends on the mode of operation of the turbine generator set: for example, starting, stopping, operating in island mode, operating in parallel with other units, or operating in parallel with a utility source. The system consists of the turbine speed transducer (magnetic pickup), the speed monitor, turbine T5 temperature thermocouples, temperature input module, electronic fuel valve, and the programmable controller software files. The governor system maintains generator frequency and/or generator load distribution (when operating in parallel) by controlling turbine fuel flow. Output current to the fuel actuator provides the mechanical interface to the electronic fuel valve. The system includes provisions for selection of isochronous or speed droop modes

of operation. The transfer from droop to isochronous and isochronous to droop is bumpless. Speed set-point adjustment is by means of speed increase and speed decrease momentary push buttons on the turbine control console. A solid-state combination generator control module (CGCM) provides load sharing between multiple units and is specifically designed to interface with the programmable controller to provide an integrated power generation control solution. Each generator's load is continuously measured by the respective CGCM and compared to other units on the same bus via interconnect circuits, facilitating equal real and reactive load sharing between the units. Turbine engine temperature (T5) is also an input to the governor control. When turbine temperature exceeds rated levels, fuel flow is then controlled based on temperature rather than speed or load inputs. In the case of a generator paralleled with an infinite bus (utility), the temperature control limits the load-carrying contribution of the unit to its rated full-load capacity for the current ambient temperature conditions. When the generator is not paralleled with the utility, the temperature control is set to a higher temperature to allow momentary operation in excess of rated load during on-load transients. T5 Temperature Limiter. Limits the real load (kW) on a unit operating in parallel with a large power source, such as an electric utility or other infinite bus system at the maximum unit rating for any ambient temperature condition. The system limits the kW load by limiting T5 temperature to a predetermined factory-set level. When the predetermined temperature level is reached, the limiter takes control of the throttle and prevents any further increase in temperature and, thus, load. The unit continues to operate at this full site-rated load for the current ambient temperature. With changes in ambient temperature (engine air inlet temperature T1), the limiter adjusts the load to maintain a constant T5 temperature, thus, automatically maintaining the unit at full site-rated load at all times. If the application periodically requires operation at a specific constant load level, rather than full site-rated capacity, then the optional kW controller should be used. The T5 temperature limited system is a part of the turbine temperature control and indication system and its set point can be viewed from the VDU.

GENERATOR CONTROL AND PROTECTION General. Combining several generator control components into one powerful package, the combination generator control module (CGCM) provides more flexibility and accessibility to specific generator control options. The CGCM (Figure 6) combines load share, synchronization, voltage control, reactive power control, and generator protection functions into one module. The CGCM communicates with the programmable controller via high speed ControlNet 1.5 (Figure 7). The module performs synchronization in combination with the programmable controller software program and voltage regulation via the control of the exciter field current. The module senses the three-phase voltage and the threephase current via PTs and CTs. The module provides real load-sharing and reactive load sharing. Reactive load sharing can be reactive droop or reactive differential (cross-current compensation). Auto Synchronizing. The control system includes an auto synchronizer for the closure of the unit circuit breaker. Upon sending an initiate synchronization discrete signal, the auto synchronizer brings the generator into frequency, volt-

Figure 6. Combination Generator Control Module (CGCM)

Figure 7. Typical Generator, Exciter, and Regulator System 6

age, and phase compliance and sends a signal to close the unit circuit breaker. The error signal for the voltage and phase comes from the CGCM. The communication is via ControlNet 1.5. KW Control (Optional). Controls the real kilowatt load on a generator operating in parallel with an infinite bus or other large source. Three types of kW load control are available: 1. KW Import Control The kW import control system controls the real load (kW) on a unit operating in parallel with a large source such as a utility. The import control monitors the load that is being imported from the utility source and adjusts the turbine generator output to maintain a preset amount of minimum load. The import control allows the import of unlimited power while maintaining the minimum power. This control is for applications where it is desired to prevent any power from being exported to the utility. 2. KW Control The kW control system controls the real load (kW) on a unit operating in parallel with a large source. The control monitors the load carried by the turbine generator set and adjusts turbine fuel flow to maintain a constant load under conditions of varying infinite bus frequency. The turbine T5 limiter system provides protection against excessive kW load while in parallel with an infinite source. The kW control system provides additional operational flexibility by allowing unit kW load level to be set at any desired constant level within the capacity of the unit. In this mode, the unit may be carrying the entire load within the plant, while the remaining unit capacity is being exported to the utility. In addition, the kW control set point can be the manipulated variable in the process control loop. For example, to modulate steam production in a cogeneration application, the steam production control could modulate the kW control set point. 3. KW Export Control The kW export control limits the amount of power that is being exported to the utility or large source. The amount of power that is being exported is limited to a preselected value. If the selected value exceeds the turbine capacity, then the T5 limiting control protects the turbine against excessive kW load. 7

VOLTAGE REGULATION Steady-State Stability Steady-state voltage regulation is defined as constant frequency and load. When the generator is operating steady state at any load, the generator voltage varies no more than 0.1%. No Load to Full-Load Accuracy At constant frequency and at rate power factor, the voltage regulation varies no more than 0.25%. Automatic Voltage Regulator (AVR) The voltage adjustment range about the selected nominal value is 10%. The resolution of the voltage is 0.1%. Voltage metering accuracy is 0.2%. Field Current Regulator (FCR) The current regulation mode allows the operator to adjust the field current manually. This gives the operator a manual voltage regulator. During the FCR mode, the automatic voltage regulator is disabled. It is important to note that the FCR is not the equivalent of an independent manual voltage regulator, since it uses some of the same circuitry as the automatic voltage regulator. CONTROL AND PROTECTION Reactive Voltage Droop Reactive voltage droop is possible through the use of a single externally provided current transformer (CT). The voltage droop is adjustable for a maximum of 10% droop at 0.8-power factor and full rated load of the generator. Reactive droop, cross-current compensation and no droop voltage control are selectable via ControlNet 1.5. Cross-Current Compensation The cross-current compensation method of paralleling is possible with other controllers of similar type. This uses the same CT that is used if reactive voltage droop is selected instead of crosscurrent compensation. KVAR/Power Factor Control (Optional) This feature maintains a constant reactive load (kVAR) output or constant power factor (pf) on the generator set when the unit is operating in parallel with a large source. Power factor and kVAR control can be enabled or disabled by the operator from the VDU. The operator can also

select whether to use kVAR control or power factor control and set the set points from the VDU. Kilowatt Load Sharing The load-sharing circuitry provides the ability to communicate with another CGCM, such that two or more generator sets may equally share load when running in parallel. Also, the CGCM will load share with older controls from Solar, such as the LSM module or Woodward 2301 governor. The load sharing between generators of unequal rating is proportional to their rating. Over-Excitation Limiting The over-excitation limiter senses field current and responds in less then three cycles. When field current exceeds the limits, the limiter function overrides the action of the CGCM AVR, VAR, or power factor modes and limits the current to the preset level. Under-Excitation Limiting Under-excitation limiting (UEL) limits the decrease in excitation to prevent loss of synchronization and excessive end-iron heating during parallel operation. Line Drop Compensation Line drop compensation is a function of generator output current. Both the real and the reactive component of the current are used. The compensation is based on the magnitude of the line current. It is adjustable from 0 to 10% of rated voltage. Voltage Input Signal The voltage regulator sensing uses three-phase signals. Current Input Signal The CGCM uses 5-amp nominal inputs. The accuracy is 0.2% of full scale. Protection The protection functions are designed to diagnose and respond to the following events: Over-excitation voltage (59F) Generator over voltage (59) Generator under voltage (27) Loss of sensing (60FL)

Loss of PMG (27) Loss of excitation (40Q) Over frequency (81O) Under frequency (81U) Reverse power (32R) Phase rotation error (47) Over current (51) Rotating diode monitor (58) Reverse VAR (40)

Over-Excitation Voltage. The over-excitation voltage protection has a timed over-excitation trip. The timed over-excitation protects the controller and generator from long-term field forcing conditions. Generator Over Voltage. The unit has an overvoltage monitor adjustable from 100 to 140% of rated voltage in 1% increments. Generator Under Voltage. The unit has an under-voltage monitor adjustable from 60 to 100% of rated voltage, settable in 1% increments. Loss of Sensing. When the generator voltage falls below 15% of the rated generator voltage, a loss of voltage sensing annunciation occurs. The loss of sensing function is supervised by the loss of operating power function and does not become active until operating power reaches its minimum threshold. Loss of PMG. A loss of PMG fault is issued within three cycles (50 msec) if PMG power input is lost. Loss of Excitation. A loss of excitation protection fault is issued in order to protect against a reverse VAR condition in the event the excitation current is lost. Over Frequency. When generator frequency exceeds rated frequency for a specified amount of time, an over-frequency fault is annunciated. Under Frequency. When generator frequency falls below the rated frequency for a specified amount of time, a definite time under-frequency fault is annunciated. Reverse Power. The reverse power protection pickup level is settable from 1 to 50% of rated generator power in increments of 1%. This feature considers real power only.

Phase Rotation Error. When possible and enabled, a phase rotation check is performed prior to initiation of breaker closure. Over-Current Protection. Over-current protection must be provided with a short inverse time characteristic, Basler Electric Time Characteristic curve S2, 99-1595. This feature is active if excitation is enabled. Rotating Diode Protection. The rotating diode monitor is capable of detecting one or more open or shorted diodes in the rotating field. If a failed diode is detected, a fault is issued. Reverse VAR. When excitation current is lost and the reverse VAR level exceeds the rated value for a definite amount of time, a reverse VAR fault is annunciated. OPERATOR INTERFACE The control system operator interface has two major components: the turbine control panel and the video display unit. Turbine Control Panel The turbine control panel (Figure 8) provides the essential controls to start or stop the turbine, to adjust the gas generator speed, and other optional control functions. Some typical gas turbine controls and indications that appear on the control panel include the following: Operation Switches

Emergency Stop (shutdown without

cooldown)

Normal Stop (shutdown with normal noload cooldown)

Speed Control (increase and decrease) Start Horn Silence (audible alarm) Acknowledge (alarms and shutdowns) Backup System (Active/Reset)

Operation Indication Lights

Starting Backup Active Stopping

Onskid Video Display Unit The video display unit is used to present an extensive selection of the turbomachinery operating parameters. The display system consists of several screens organized by systems and functions to allow the operator to easily locate and monitor a given parameter. It also includes a passwordprotected screen, which allows the operator to input or modify certain values such as process control set points. The onskid VDU makes use of Solar's TT4000S display and monitoring system, which performs several key functions to facilitate operation of the turbomachinery equipment through a user-friendly interface. The TT4000S system monitors the turbine and driven equipment parameters, annunciates alarms, reports on the running status of the equipment, and provides a comprehensive set of analysis tools. Data storage consists of an alarm / event log containing the last 5000 events, five trigger logs containing one-second tag samples surrounding the last five shutdowns, and an hourly log containing snapshot data for the last 12 months. The TT4000S display and monitoring system uses the Embedded Windows NT operating system and offers the following industry standard features: Complies with Transmission Control Protocol and Internet Protocol (TCP/IP) Supports Object Linking and Embedding for Process Control (OPC) Supports ActiveX controls Can be integrated as part of a local area network for sharing of data or remote display communications 9

Off/Local/Remote (control selector with

lockable positions)

Figure 8. Operator Interface

Standard Display Screens The display screens listed below are for a typical package and are provided as standard equipment for all turbine packages: Main Menu Operation Summary Engine Temperature Shaft and Bearing Lube System Generator Summary Bus Summary Generator Control Modes Generator Set Points Gas Fuel System Liquid Fuel System Enclosure Alarm Summary Alarm Log Event Log Strip Chart Maintenance Modes VFD Configuration

Figure 10. Typical Operation Screen generator data, control mode, fuel command status, fuel selection, operation mode, shutdown status, and lube pump operation. This screen also displays the starting and stopping sequences. During the package start sequence, the VDU shows the various logic and timed sequences involved from initiation of start-up to running condition. This feature is a valuable troubleshooting resource for operations personnel to quickly identify the source of the starting problem and, thus, reach a faster solution. Engine Temperature Display Screen. (Figure 11) This screen displays all the turbine-related temperatures monitored on the unit. The screen displays each individual thermocouple temperature, as well as the calculated averages.

Menu Screen. (Figure 9) This screen provides the operator the ability to view the selectable view screens.

Figure 9. Typical Menu Screen Operation Summary Screen. (Figure 10) This screen provides a view of the overall gas turbine and driven equipment operating parameters. The screen displays turbine engine temperatures,

Figure 11. Typical Engine Temperature Screen

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Shaft and Bearing Screen. (Figure 12) This screen shows a bar graph representation of the vibration levels of the engine and generator as detected by the vibration monitoring system. The screen displays the bearing temperatures for engine and generator.

Figure 14. Typical Generator Summary Screen Bus Summary Screen. (Figure 15) This screen is a summary of the real-time generator and customer bus operating data system provided by the control system, including Circuit Breaker Trip and Auto Sync Initiate control.

Figure 12. Typical Shaft and Bearing Screen Typical Lube System Screen. (Figure 13) This screen displays all pertinent data for the lube oil, such as pressure, temperature, and the status of the pumps, along with the manual backup pump test function.

Figure 15. Typical Bus Summary Screen Generator Control Screen. (Figure 16) This screen allows the operator to view the status of the various generator control modes and to select the control mode desired through the use of popup screens. Generator Set-Point Screen. (Figure 17) This screen allows the operator to change set points by means of a pop-up screen or the local Increase/Decrease switch. The set point and actual values are viewed from this screen as well.

Figure 13. Typical Lube Oil Screen Generator Summary Screen. (Figure 14) This screen is a summary of the real-time generator operating data provided by the control system, including operating modes, set points, along with AC calculated and monitored values.

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Figure 16. Typical Generator Control Modes Screen

Figure 18. Typical Gas Fuel Screen

Figure 19. Typical Liquid Fuel Screen Figure 17. Typical Generator Set-Point Screen Gas Fuel Screen. (Figure 18) This screen displays all of the pertinent data for the gas fuel system, such as pressure, flow, actuator, and status of the fuel valves. For a dual fuel system, the operator can transfer fuels from this screen. Liquid Fuel Screen. (Figure 19) This screen displays all of the pertinent data for the liquid fuel system, such as pressure, flow, actuator, and status of the fuel valves. For a dual fuel system, the operator can transfer fuels from this screen. Enclosure Screen. (Figure 20) This screen displays information related to the enclosure devices, such as fan, temperature, and gas sensor.

Figure 20. Enclosure Screen

12

Alarms Summary Screen. (Figure 21) This screen displays all alarm and shutdown annunciations with a time and date stamp. Alarms are time stamped in the order in which they are received from the programmable controller. On the display, alarms are shown in yellow and shutdowns in red. Unacknowledged alarms are shown in reverse video. As the malfunctions are acknowledged, they stop flashing and are shown in the corresponding colored text until they are cleared from the system and the Reset switch is pressed. The first four malfunctions detected are displayed at the top of all screens until cleared. Figure 22. First Out Alarm Screen Discrete Event Log. (Figure 23) This feature monitors and records the changes in status of all defined discrete (switch or binary) inputs. These include operator command, alarms and shutdown annunciations, and key sequencing and status signals. They are displayed as a chronological, time-stamped listing of events in the order in which they occurred. It is possible to have multiple events with the same time stamp due to the update rate of the display system. Up to 500 events can be stored in the log. Events can be selected by double clicking on the column heading. Right clicking anywhere on the screen and selecting the Reports menu can easily create reports. This feature provides a historical record of sequence and status events that changed. It can be used to audit package operation or to identify malfunctions that have occurred and areas of the operation that need attention.

Figure 21. Typical Alarm Summary Screen First Out Alarms Display Screen. (Figure 22) This screen displays the order in which alarms occurred. The resolution of the alarm order for this feature is the time of one programmable controller scan. These data are obtained by reading the controller's first out alarm buffer, starting at the first unacknowledged alarm. The controller updates this buffer each scan. Only unacknowledged alarms appear on this screen. Up to 22 alarms can appear. Note: If the First Out Alarms display is to be used to diagnose a shutdown, the Acknowledge button on the control panel must not be pressed. Pressing the Acknowledge button does not eliminate unacknowledged alarms from the controller's alarm buffer, but it changes an alarm index so that the First Out Alarms display cannot access them. As long as the Reset button is not pressed, however, the unchanged contents of the controller alarm buffer can be viewed as described above.

Figure 23. Typical Discrete Event Log Display Screen 13

Strip Chart Function. (Figure 24) This function emulates a 10-pen strip chart recorder. The screen displays in real-time up to 10 variables selected by the operator. Parameters are selected by assigning each pen a value; the values can be analog or binary data available for monitoring. Each pen can be assigned different colors, line weights, and symbols to make each monitored value easily distinguished from one another. The bottom of the strip chart screen displays the corresponding legend for each pen. Each of the plots is scaled for the selected variable and displays the actual numerical value for each variable. The date range and scaling can be changed by double clicking on the desired pen to bring up the configuration pull-down menu. The time axis on the strip chart can be configured for each pen by date, hours, minutes, or seconds. The "zoom" feature allows the user to zero in on the particular area of interest.

Figure 25. Typical Maintenance Screen VFD Configuration Screen. (Figure 26) This screen allows the operator to configure the VFD motors and monitor the performance of the motors.

Figure 24. Typical Strip Chart Screen Maintenance Screen. (Figure 25) This screen allows users to perform routine maintenance on the turbine and displays information such as engine hours and engine starts. Figure 26. Typical VFD Configuration Screen

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Optional Control and Display Features

Other hardware and software options are available that provide additional flexibility and capability to the basic programmable controller control system. These software, control and display features are described in this section. ENGINEERING UNITS The following engineering units are available for display purposes: Type English Metric (SI) Metric Metric Pressure psig kPa bar kg/cm
2

cal logic and constants accessible. Limited security to prevent inadvertent programming changes is built in, but predetermined programming alterations are possible with appropriate software. Programming Terminal. A computer specifically configured for programming the programmable controller control logic and sequences is provided, along with software and a programming manual to allow for field programming of the control system logic within the control system. Programming Kit. The field programming kit includes software, programming manual, and a PMCIA Type II interface card to allow field programming of the control system and logic. LANGUAGE The turbomachinery package labels, control console labels, and operator interface screen displays are available in numerous languages. For languages available, please contact a Solar Turbines representative. COMMUNICATIONS TURBINE CONTROL TO SUPERVISORY SYSTEM Communication between the gas turbine control system and the user's supervisory control and data acquisition (SCADA), distributed control system (DCS), or other supervisory system is available. Turbotronic 4 control systems can be provided with an interface that allows the supervisory system to communicate with the programmable controller, obtain data, and have the control capability required. Data for Transmission The following information from the turbine package is available to be accessed by the supervisory system: 1. Analog instrumentation values 2. Discrete status values 3. Discrete alarms and shutdowns The following information can be sent by the supervisory system: 1. Discrete control commands (start, stop, acknowledge/reset, and change mode of operations) 2. Analog operating set points (kW control, speed, kVAR, pf, and voltage) 15

Temp. F C C C

Length inches mm mm mm

FIRE DETECTION AND SUPPRESSION SYSTEM A fire detection system is available for installation in the enclosure. The primary fire detection system uses ultraviolet (UV) detectors. The system includes an automatic optical integrity feature, which provides a continuous check of the optical surfaces and detector sensitivity. The secondary detection system uses ratecompensated thermal detectors. The two detection systems act completely independent in detecting a fire. A fire system supervisory release panel is furnished whose primary purpose is to supervise the fire system circuitry. An open circuit, ground fault condition, or loss of integrity in the electrical wiring results in a trouble signal. If a fire is sensed, the detectors transmit an electrical signal via the fire system controller and the fire system supervisory panel to activate the fire suppression system. In receiving this signal, the explosionproof control heads activate the discharge valves on the primary and extended extinguishing cylinders, releasing the extinguishing agent into the enclosure and pressurizing the trips that close all vent openings. The fire suppression system achieves a static air condition and then floods the enclosure with the proper concentration of suppressant to extinguish the fire. FIELD PROGRAMMING One characteristic of the control is that it can be reprogrammed using optional software with criti-

The specific addressing for the data transfer is provided for each turbine package. Protocol The communication language used between programmable controller systems usually follows a set of rules or format called a protocol. The protocol defines the sequence and organization of the transmitted data. The RSLogix controller uses an internal proprietary bus protocol called control and information protocol (CIP). Communication modules allow different communication networks to interface with this internal bus. Certain arrays of information inside the controller can be configured to mimic PLC-5 data tables that support the DF1 protocol. The user's supervisory system must be programmed to handle the CIP, DF1, or Modbus protocols. The Allen-Bradley communications software RSLinx provides all the

necessary drivers to communicate with all turbine package control networks and network devices (except Modbus) and is required for most applications. Supervisory Interface Options There are many ways to interface with the gas turbine control system. The most common include serial communication (RS232, RS422, RS485), Ethernet TCP/IP, ControlNet 1.5, and Modbus. See Figure 27 for a typical communication network layout. Each communication network has certain advantages and disadvantages that need to be considered when selecting a network for a particular application. Below is a description of each network to help select the optimum interface for the users application:

Remote Video Display Unit

Basic Configuration Options

RS232 Modbus Ethernet TCP/IP
SCADA/DCS

Auxiliary Video Display Unit with CNet1.5 PCIC Line Printer

Ethernet RS232 KFC15

ControlNet Module

Onskid Control Box

Ethernet Module Modbus Module Backup Relay Shutdown System Flex I/O (Normal Input/Output) Redundant ControlNet 1.5

ControlLogix

Hardwire Interconnect VFD(s)

Heat Recovery System

ControlNet 1.5 (NAP connection) Local Programming Terminal (for use during commissioning)

Figure 27. Typical Communication Network Layout

16

ControlNet 1.5 This is an Allen-Bradley developed proprietary field bus network. Data transmission rates are high, the communication is deterministic, and all interface modules can be configured for redundant media.

Typical Application. The turbine package Ethernet module is usually connected to a local hub that is connected to an Ethernet backbone for data transfer to a remote supervisory system over longer distances. 10BaseFL fiber lines support 2000 m (6560 ft) segments. Modbus Slave The Modbus protocol is an open, published and widely implemented protocol. It is used to transfer I/O and register data between Modbus control devices.

Physical media: quad shielded RG-6U

coaxial cable

Protocol: CIP Topology: Trunk line/drop line,

star with repeaters

Maximum distance (per Rockwell

specifications): 1000 m (3280 ft) with 2 nodes, 250 m (820 ft) with 48 nodes

Physical media: shielded twisted

conductors

Maximum data transmission rate: 5 Mbps Maximum number of nodes: 48

Typical Application. This is the control network used to connect the distributed I/O modules to the controller for turbine control. Onsite, VDUs are typically connected directly to this I/O network via PCC or PCIC cards installed in the computer. Supervisory interface (RS232C) with the turbine via ControlNet is allowed only through a serial link connection module (KFC15) or a separate ControlNet network that is not directly connected to the turbine I/O network. The maximum distance and number of nodes allowed for the network can be increased by adding repeaters and/or by using optical fiber media. Field programming terminals can connect to the network via the network access port (RJ-type) located on the interface module or Flex I/O adapters. Current ControlNet 1.5 networks and network devices are not compatible with older ControlNet 1.25 networks or network devices. Ethernet TCP/IP Data transmission rates are high, the communication is non-deterministic, and cabling and connectivity is well known throughout most industries (common office computer network technology).

Protocol: Modbus RTU Topology: point-to-point (RS232/RS422)

or multi-drop (RS485)

Maximum distance (per Rockwell

specifications): 15 m (50 ft) for RS232, 1219 m (4000 ft) for RS422/RS485 115.2 kbps

Maximum data transmission rate: Maximum number of nodes: 32 (RS485)

Typical Application. The Modbus Interface option gives the turbine package control system the ability to communicate with a Modbus master device through a serial interface (RS232, RS422, or RS485). The turbine package control system acts as a Modbus slave device using a subset of the RTU version of the Modbus protocol. The user provides the Modbus master device, which may be a supervisory control system, a data acquisition system, a central or plant control system, a remote monitoring system or some other computer system. Remote RS232/422/485 Serial Link Serial link communication allows connectivity of devices without special communication modules to communication networks.

Physical media: twisted pair (10BaseT) Protocol: CIP over TCP/IP Topology: star Maximum distance (per Rockwell specifications): 100 m (328 ft) to hub

Physical media: shielded twisted

conductors

Protocol: N/A Topology: point-to-point (RS232/RS422)

or multi-drop (RS485)

Maximum distance (per Rockwell

Maximum data transmission rate: 10 Mbps Maximum number of nodes: unlimited

(8 to 24 nodes per hub typical)

specifications): 15 m (50 ft) for RS232, 1219 m (4000 ft) for RS422/RS485

17

 Maximum data transmission rate: 20 kbps

(RS232), 100 kbps @ 4000 ft/10 Mbps @ 40 ft (RS422/RS485)

Maximum number of nodes: 32 (RS485)

Typical Application. A remote serial link is provided to allow a remote supervisory system to send and receive data to and from the ControlNet network via an external Allen-Bradley KFC15 communication module (RS232). Supervisory serial interface through the DH+ network using a remote KF2 interface module is not advised, since this device can only handle local messaging (communication through other remote networks is not allowed). The application software on the remote supervisory system must handle either DF1 or CIP communication protocols. VIDEO DISPLAY OPTIONS Auxiliary Video Display Unit The auxiliary video display unit (VDU) consists of an industrial desktop computer and the TT4000 display and monitoring system. The auxiliary VDU has all the features of the standard skidmounted VDU plus the following enhancements: Additional Historical Data 2-Minute Log. 1 month of daily files with data points taken every 2 minutes 10-Second Log. Data are read at 10second intervals for the last 14 days. Larger Trigger Log. The Trigger Log function stores up to 25 triggered files, each containing 6 minutes of 1-second data points. (The onskid VDU stores 5 triggered files.) Accommodates Additional Options Gas turbine performance calculations and display Printer Remote VDU Higher Resolution Screen More Memory, including RAM and Non-Volatile Storage Incorporates Visual Basic for Application (VBA) DVD Reader / CD Writer

The auxiliary VDU communicates with the onskid controller through ControlNet 1.5. The total ControlNet cable run must be no longer than 762 m (2500 ft). Cable run lengths for the auxiliary VDU vary from project to project depending upon how close the motor control center is to the gas turbine. Typically, the cable run without the auxiliary VDU is less than 150 m (500 ft), leaving 610 m (2000 ft) for the auxiliary VDU cable run. Note: these distances are reduced if high flex cable is used. Remote Video Display Unit The remote video display unit (VDU) option consists of an industrial desktop computer equipped with TT4000. The remote VDU has all the features of the auxiliary VDU with the exception that some of the operational privileges are limited at the remote VDU. For example, lockout shutdowns cannot be reset remotely. The auxiliary VDU option is a prerequisite for the remote VDU option. The remote VDU communicates with the auxiliary VDU through Ethernet. The Ethernet interconnect is the responsibility of the customer. Distance is limited only by the customers network. Both the remote VDU and the auxiliary VDU come with an Ethernet port and modem. The viewing of historical data from the remote VDU may be noticeably slower depending upon the speed of the customer-supplied network. A gas turbine performance map for the predicted rating of a gas turbine at standard conditions is displayed on the VDU (Figure 28). Algo-

Figure 28. Gas Turbine Performance Map

18

rithms convert site data to standard conditions and the operating point is displayed real time on the map at the intersection of X and Y cursors. Digital values for the predicted power, inlet air temperature, gas turbine temperature, fuel flow, and compressor discharge pressure are also displayed on the screen. A key performance indicator is provided for display by calculating the differential value (actual minus predicted) of the digital values. The trend of these parameters provides a true indication of performance degradation since the data are standardized for the actual operating point and not just optimum. Information gained from this feature can point to corrective and diagnostic action required, such as washing the compressor and borescoping the hot gas path.

Printer/Logger Option This option is available with the auxiliary VDU. It includes a printer, cable, and software and provides for a variety of reports and event logging. Features provided are:

Alarm and Shutdown Log Prints one

event per line with time and date stamp.

Reports On demand, prints current values of standard analog variables and calculated variables. Standard totalized variables may be printed also. Print Screen On demand, prints any screen that is currently being displayed.

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Appendix A: Hardware
PHYSICAL HARDWARE Programmable Controllers Allen-Bradley ControlLogix I/O Allen-Bradley Flex Modules Voltage Regulator Basler Electric/Allen-Bradley Combination Generator Control Module (CGCM) Onskid Display Allen-Bradley 6181 Power Supply 120 Vdc to 24 Vdc Transducers 4 to 20 mA RTDs Platinum 100 Ohms a = 0.00385 Control Enclosure NEMA 4 or NEMA 4X Backup Controls Backup overspeed box Backup relay shutdown system Internal Wiring 20 gauge, typical 22 gauge for low level shielded wire 12 gauge for most power wire Wire identification, branded every 152 mm (6 in.) All customer connects are to Flex I/O or terminal blocks on DIN rail ELECTRICAL SPECIFICATION Input Power Internal Power Input Signals 120 Vdc 24 Vdc Discrete signals, 24 Vdc Analog signals, 4 to 20 mA Low level temperature RTD High level temperature thermocouple Speed signal magnetic pick-up Discrete 24 Vdc, 0.5 amp max. Discrete 24 Vdc, 2 amps max. Analog signals, 4 to 20 mA 24 Vdc, 3 to 10 amps 120 Vac,12 amps

Output Signals Relay Rating

ENVIRONMENTAL SPECIFICATION Operating Temperature Storage Temperature Relative Humidity Vibration Area Classification 0 to 60C -40 to 85F 5 to 95% non-condensing 1g peak 5 to 20 Hz Nonhazardous

RFI/EMI SUSCEPTIBILITY AND EMISSION Similar equipment has been tested to the specification list below and passed the test successfully: IEC 801-2 IEC 801-3 IEC 801-4 IEC 801-5 IEC 801-6 CISPR/B CISPR/B Electrostatic Discharge Level 3 Radiated Immunity Level 3 Fast Transient/Burst Level 3 Electrical Surge Immunity Level 3 Conducted Emission Level 3 Conducted Emission Class A Radiated Emission Class A 20

Appendix B: Technical Supplement

HARDWARE INFORMATION ControlLogix Processor. The Allen-Bradley Logix5555 processor has 1.5 Mbytes of user memory and can be connected in a variety of networks for interconnection with computers, distributed processing, and distributed I/O: General Specifications Processor for Logix5555 Environmental Conditions Operational Temperature Storage Temperature Relative Humidity Vibration Operating Electrical Specifications Operating Voltage Integrated Battery

1756-L55M13 0 to 70C (32 to 158F) -40 to 85C (-40 to 185F) 5 to 95% (without condensation) 10 to 500 Hz, 2.0 g maximum peak acceleration

19.2 to 32 Vdc (24 Vdc nominal) Each Logix5555 processor is shipped with a battery installed for memory backup (part number 1756-BA1).

ControlLogix Power Supply. Used with the 1756 chassis to provide power directly to the chassis backplane: Model Input Voltage Input Power Backplane Output Current 1756-PB72 24 Vdc 97 W 1.50 A @ 1.2 Vdc 4.00 A @ 3.3 Vdc 10.0 A @ 5.0 Vdc 2.80 A @ 24 Vdc

Discrete Input Modules. These modules receive input from on/off devices such as level switches, pressure switches, push buttons, relays and protective equipment: Model Channels Signal 1794-IB16 16 10 to 32 Vdc

Discrete Output Module. This module drives devices such as solenoid valves and motor contactors. Current Rating Model 1794-OB16P 1794-OB8EP Channels 16 8 Signal 10 to 32 Vdc 19 to 32 Vdc Per Channel 0.5 2 Per Module 8 10

Analog Input Modules. Some modules accept signals from high-level output devices, such as current transmitters; others accept low-level signals, such as from RTDs. Model 1794-IE8 Series B Channels Signal Rating

8 4 to 20 mA, 0 to 20 mA, 10 V, 0 to 10 V 21

Model 1794-IJ2 Channels Inputs per Channel Frequency Usage Model 1794-IRT8 Channels Inputs Ranges Usage

2 2 (frequency and gate) 32,767 Hz max. Fast, high resolution speed measurements

8 -40 to +100 for thermocouples 0 to 325 mVdc for RTDs 0 to 500 ohm for resistance range High-speed module used for temperature measurements. Separate scaling and cold junction compensation is required.

Analog Output Modules. These modules are used for drive-positioning devices such as the fuel throttle valve and to provide analog signals to other instrumentation. Model 1794-IE8 Series B Channels Output Current Output Voltage HARDWARE CERTIFICATION In general, Allen-Bradley components are SA and ATEX certified for Class I, Division 2, Zone 2, Groups A, B, C, and D. AREA CLASSIFICATION Nonhazardous. QUALITY ASSURANCE Complete control systems are put through three test phases at Solar: static test, pre-test, and final test. Further tests are made during installation and commissioning. 1. Static Test. Verifies the correct console wiring and software was installed, including the standard options and nonstandard features required for the project. 2. Pre-Test. The controller is mated with the unit it is shipped with and is used to verify correct skid wiring and certain statically tested functions. 3. Final Test. The unit is operated with its control system, where final package and control tests are made. The software used for this test is the as-shipped software (excluding Titan gas turbines). 4. Commissioning. During commissioning tests onsite, any further software changes that are found to be necessary are included in the as installed software. CONTROL CONSOLE LAYOUT The basic arrangement for the programmable controller is to have one seven-slot 1756 I/O chassis and power supply similar to the one seen in Figure 29. The programmable controller module is in the leftmost slot and all other applicable modules occupy the six remaining slots. This assembly is mounted on a panel (Figure 30) attached to the back wall of the console.

4 4 to 20 mA, 0 to 20 mA 10 V, 0 to 10 V, 5 V, 5 V

22

Figure 29. ControlLogix Chassis Configuration

Figure 30. Generator Control Panel and Turbine Control Panel Internal Configuration

23

Appendix C: Control System Information

TURBOTRONIC DEFINITIONS Control Processor. The central controlling device. Turbotronic 4 uses the Allen-Bradley ControlLogix processor, which replaces the programmable logic controller (PLC5) used on earlier systems. HMI. Human Machine Interface the generally accepted industry term for display and monitoring systems, such as Solars TT4000 product. Onskid. Located on and permanently attached to the turbomachinery package skid. Remote. Located someplace other than the turbomachinery area and control room, usually at some distance away in an unclassified area. Remote HMI implies a secondary HMI system in addition to the primary HMI. TT4000. A Windows 2000 based display and monitoring system that is available with the Turbotronic 4 system. Turbotronic 4. Solar Turbines new package and control system. VDU. Video Display Unit a generic term for a computerized display device. HUMAN MACHINE INTERFACE DESCRIPTIONS TT4000. Solars fully featured display and monitoring system consisting of a desktop PC (A-B 6155) configured with the Windows 2000 operating system, the TT4000 application software, and the specific project software files. It provides extensive data storage capabilities in addition to display, communications, and control capabilities. It is designed for operation in a nonhazardous area such as a control room. TT4000S. A version of Solars TT4000 software, which is installed in an onskid VDU (A-B 6183) and makes use of the Windows Embedded NT operating system. It provides display, communications, and basic control capabilities at the package skid. It provides only limited data storage capability. TT4000 Remote. This is the version of TT4000 installed on a remote PC (A-B 6155). It mirrors the functionality of the primary TT4000 system. Important Note TT4000 is provided only as a complete system installed, configured, and tested on computer hardware supplied by Solar. This hardware must be dedicated to the TT4000 system and no other software may be loaded. This is necessary to protect the integrity of the system and avoid any potential interaction with other software. SYSTEM DESCRIPTIONS Figure 31 shows the various components that make up the Turbotronic 4 control system. Auxiliary Desktop PC The TT4000 display and monitoring system installed in a desktop PC. This PC must be located no more than 762 cable m (2500 cable feet) from the package skid. Onskid Control System The control system is mounted in one or more panels attached to the package skid. The panels contain the key elements of the system, including the control processor, the I/O modules, the vibration monitoring system, and the TT4000S display system. Packages with onskid controls may only be installed in a nonhazardous area. Remote Desktop PC A secondary TT4000 display and monitoring system installed in a desktop PC, providing remote monitoring and control of the turbomachinery package. This PC must be linked to the primary TT4000 system via a network connection. The distance between this PC and the primary TT4000 system is limited only by the capability of the network.

24

TT4000S

CONTROLNET CONTROL PROCESSOR AND I/O TT4000 DESKTOP

ETHERNET OR OTHER TT4000 REMOTE

Figure 31. Turbotronic 4 Control System Outline

25

FOR MORE INFORMATION Telephone: (+1) 619-544-5352 Telefax: (+1) 858-694-6715 Internet: www.solarturbines.com

Solar Turbines Incorporated P.O. Box 85376 San Diego, CA 92186-5376 U.S.A.

SPTT-PG/802