Download - Woodward 505e
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PART I
505E TURBINE CONTROL
&
TURBINE INTERLOCK SYSTEM
KEBB 2X150 TPH + 1X32MW COAL BASED POWER PLANT
PT. PETROKIMIA GRESIK, EAST JAVA
PREPARED BY :
NAME : ARIPIN
HP: 081320009898
EMAIL : [email protected]
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505E TURBINE CONTROL
The 505E is 32 bit microprocessor based control to control speed ( or load) turbine and steam extraction turbine.
Turbine Control Device : Type : 505E
Version : 2.06-6A
Manufacturer : WOOWARD, FORT COLLINS CO, USA.
Electrical Configuration :
1. Power Supply input : 24 VDC (18 32VDC, 77VA max, 6.25A internal fuse) 2. Signal for HP Servo valve : 1 point, 4-20mA 3. Signal for LP Servo valve : 1 point, 4-20mA 4. Analog Input point : 6 points, 4-20mA 5. Analog Output point : 6 points, 4-20mA 6. Digital Input point : 16 points, 18 26VDC 2.5mA. 7. Digital output point : 8 points (NO/NC). 8. Aux. Power : 7 points, 24VDC 200mA max. 9. Speed Sensor input : 2 points (MPU = passive, Proximity Probe = active) 10. Serial Communication Ports : 2 ports (Modbus communication : RS-232, RS-422, RS485)
FUNCTION OF BUTTON
1. PRGM (Program) : to change all parameter (shutdown mode)
2. RUN : to Activate the 505E
3. STOP : to deactivate the 505E (once verification is given)
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acerText Box3
acerText Box505E Version 2.06-6A
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4. RESET : to clear all alarm
5. F1 (Alarm) : to display any alarm
6. F2 (over speed test enable) : command for over speed test.
7. F3 : (Not Programmed)
8. F4 : to enable or disable extraction, Light ON Extraction Active.
9. SCROLL : Push the button left rigt, up down to display the parameter what do you want.
10. SELECT : push the button up or down to select current display (@)
11. ADJ : to up or down the parameter (Run Mode)
12. NO (0) : enter 0 or NO button to disable our command
13. YES (1) : enter 1 or YES button to enable our command
14. ACTR (2) : to display current actuator position (Run Mode)
15. CONT (3) : to display the parameter which is in control (Run Mode)
16. CAS (4) : (Not Programmed)
17. RMT (5) : Remote speed set point control information (Run Mode)
18. LMTR (6) : to display the valve limiter information (Run Mode)
19. Speed (7) : to display current speed & setting (Run Mode)
20. AUX (8) : (Auxiliary,Not Programmed)
21. KW (9) : to display current KW & Speed (Run Mode)
22. CLEAR : Clear Program / Run Mode entries, and takes to main display
23. EXT/ADM : Enter a decimal point or displays the extraction information (Run Mode)
24. DYN : Accesses the dynamic setting of the parameter controlling the actuator position (Run Mode)
25. ENTER : Enter new values in the program mode. And allows the direct entry of the setpoint values in the run mode.
26. EMERGENCY STOP : Emergency Shutdown command for the control.
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SPEED PID OPERATIONAL MODE
The Speed PID operates in one of the following modes, depending on configuration and system conditions :
1. Speed Control ------- > Gen. And Utility Breaker are open 2. Frequency Control ---- > Gen. Breaker is Closed, and Utility Breaker is open (Single Running) 3. Unit load Control ----- > Gen. Breaker and Utility Breaker are Closed (Synchrone Running)
- Turbine HP and LP valve position control - Generator Load Control
NOTE : in KEBB Petrokimia, signal indication for Utility Breaker is looped (jump) with Generator Breaker.
When not programmed for Generator application, the 505E speed PID operates in a speed control mode at all times. When programmed for Generator application, the state of the Generator and utility breaked determine the operational mode of the speed PID.
If the Generator breaker is OPEN, the speed PID operates in a SPEED CONTROL MODE.
If the Generator breaker is CLOSED, and the utility breaker is open, the FREQUENCY CONTROL MODE is selected.
When Generator breaker and utility breaker are close, a UNIT LOAD CONTROL MODE is selected.
While in the Speed Control Mode, the Speed PID will control a turbine at the same speed or frequency regardless of the load its supplying ( up to the units load capability). With this configuration, no form of droop or second controlling parameter (KW signal) is used by the PID for stability or control.
The Unit Load PID have 2 (two) parameters to control unit load and act as a stabilizing effect for any change in bus / utility frequency. With this configuration, when bus frequency decrease or increase, unit load increase or decrease respectively.
F (frequency) ------- > kW (Load)
F (frequency) ------- > kW (Load)
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3000rpm
0
3210rpm
SP
EE
D S
ETTING
Actual Frequency set by the utility (+/- 50H
z)
50% Load
100% Load
kW LO
AD
FRE
QU
ENC
Y IS SE
T BY TH
E U
TILITY G
RID
/ PLN
LOA
D V
AR
IES
WITH
SPEED SET PO
INT
(FRE
QU
EN
CY
AN
D LO
AD R
ELATION
SHIP)
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acerText Box3180rpm
acerText Box+/- 50Hz
-
+-
PID
TOO
UTP
UT
0%E
RR
OR
1. SP
EE
D C
ON
TRO
L
SPE
ED S
ET PO
INT (U
P TO
3000RPM
)
TUR
BINE
SPE
ED (3000R
PM)
+-
PID
5% of
Rated speed
AND
0%E
RR
OR
DR
OP
CA
LC
SPE
ED S
ET PO
INT (U
P TO
3210RPM
)
TUR
BINE
SPE
ED (3000R
PM)
UTILITY
BR
EAKER
GEN
. BREA
KER
2. TUR
BIN
E IN
LET V
ALV
E P
OS
ITION
CO
NTR
OL W
ITH FR
EQ
UE
NC
Y S
WITC
H ----> S
ING
LE R
UN
NIN
G
TOO
UTP
UT
-
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acerText Box
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+-
PID
5% of
Rated speed
+-
PID
5% of
Rated speed
AN
D
0%ER
RO
R
AN
D
0%ER
RO
R
DR
OP C
ALC
DR
OP C
ALC
SP
EE
D S
ET P
OIN
T (UP
TO 3210R
PM
)
TUR
BIN
E S
PE
ED
(3000RP
M)
UTILITY
BR
EA
KE
RG
EN
. BR
EA
KE
R
TOO
UTPU
T
UTILITY
BR
EA
KE
RG
EN
. BR
EA
KE
R
GE
N. K
W
SP
EE
D S
ET P
OIN
T (UP
TO 3210R
PM
)
TUR
BIN
E S
PE
ED
(3000RP
M)
TOO
UTPU
T
3. GE
NE
RA
TOR
LOA
D C
ON
TRO
L WITH
FRE
QU
EN
CY
SW
ITCH
AN
D K
W FE
ED
BA
CK
-----> SY
INC
HR
ON
E R
UN
NIN
G
--
3. GE
NE
RA
TOR
LOA
D C
ON
TRO
L WITH
FRE
QU
EN
CY
SW
ITCH
-----> SY
NC
HR
ON
E R
UN
NIN
G
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acerText Box4.
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AC
TUA
TOR
-SERVO
3000RPM
TUR
BINE
SPEED
VALVE
LIMITER
INLET M
OTO
RIZED
VALVE
MAN
UA
L START M
OD
E
100%
0%
TIME
(EXAM
PLE : PAN
ASIA PO
WER
PLANT) Q
UIC
K C
LOSE
/HY
DR
AULIC
VALV
E FULLY O
PEN
AN
D BYP
ASS VA
LVE
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AC
TUA
TOR
-SERVO
3000RPM
TUR
BINE
SPEED
VALVE
LIMITER
SEM
I AUTO
MA
TIC STAR
T MO
DE
100%
0%
TIME
(EXAM
PLE : KEBB
PETR
OKIM
IA POW
ER PLAN
T)
QU
ICK
CLO
SE /H
YD
RAU
LIC VA
LVE FU
LLY OPEN
INLET M
OTO
RIZED
VALVE
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TURBINE START
The 505E has 3 (three) turbine start mode : 1. Manual Mode
2. Semi Automatic Mode
3. Automatic Mode
1. Check Turbine accessories ( example : EH Control Oil Pressure, Inlet Motorized Valve, Drain Valve, etc) or All important parameter to allow turbine start up. if OK --- > go to 505E.
2. Start Permissive - Open the Quick Closed Valve/ Hydraulic Valve ( Right and Left) untill fully Open, and the
limit switch will contact and send signal to 505E and DCS ----- > Fully Open - Click the 505 Run Permission Button on the Turbine & Gen Display DCS Computer,
and click YES.
3. Push RESET button - All alarms must be cleared, push the ALARM (F1) button to check alarm list if the button
is LIGHT ON (RED). - If alarm still appear, check the parameter and interlock switch. The interlocked
parameter must in safe range, and the not important parameter switch while the turbine start must be open (example : Generator Protection Switch, Vacuum protection, extraction protection).
- 505E will ramp open the LP valve ( Extraction Valve) to fully open 100%. And the HP valve ( Inlet Turbine Valve) still in the position fully close 0 %.
4. Push RUN button - The 505E in RUN mode will control the Turbine speed. - The HP Valve (Governor) will ramp open to minimum speed setting --- > 600 rpm. - And, Set the speed according to the Turbine Star up Chart.
5. Setting The Speed - Push the SPEED Button (7)
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- Push ENTER button Insert New Value Setting ( example : 12 00), and the push ENTER button.
ACTIVATE EXTRACTION NO. 2 IN 505E
1. Check Extraction No. 2 line ( Motorized Valve, drain Valve, etc.) to allow extraction no. 2 active / enable. If ready, go to 505E to enable the extraction no. 2.
2. Push F4, and then 3. Push YES /1 button to enable the Extraction. The display will change from disabled to
enabled, and F4 button will light on (red colour).
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SPEED VS EXTRACTION PRIORITY
Because an 505E has 2 (two) valve must be controlled ( Governor Inlet valve and Steam Extraction ). 505E can control 2 (two) parameter at a time. If the turbine reaches an operating limit, the result is only free moving valve to control with, thus the 505E can only control 1 (one) parameter.
In KEBB Petrokimia, Speed Priority is programmed. The 505E will only control turbine speed/load When the turbine reaches an operating limit. When programmed for speed priority, the 505E will maintain speed/load and sacrifice extraction control. With this configuration the Extraction PID is forced to lose control of its process.
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A. ENCLOSED DRAWING :
1. Control Oil HE Flow Chart 2. 505E wiring Diagram for DI/DO Points 3. 505E wiring Diagram for AI/AO Points 4. Turbine Hot Well Control Diagram 5. Turbine Alarm & Trip Setting 6. Turbine Shutdown Logic Diagram
B. ENCLOSED VIDEO : 1. 505E Button Fuction 2. 505E RUN and Speed Setting 3. 505E Extraction Activation / Deactivation 4. 505E Service Mode
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LAMPIRAN : 1 of 6K
EB
B P
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LAMPIRAN : 2 of 6K
EB
B P
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LAMPIRAN : 3 of 6K
EB
B P
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LAMPIRAN : 4 of 6K
EB
B P
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FOR
KE
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550 mm
or 850 mm
150 mm
or 450 mm
35%
8.3MP
a or 9.0 MP
a
0.89MP
a or 1.49 MP
a
-0.65 MP
a
0.13MP
a, DC
oil start
0.65MP
a, HP
pump S
tart
10.5MP
a
510C or 540C
3210rpm
95C
95C
95C
95C
95C
80C
70C
70C
70C
60C
80m
-0.6mm
or 0.6mm
20%
0.79MP
a
-0.45MP
a
0.08MP
a
0.3MP
a
9.6MP
a
110C
110C
110C
110C
110C
100C
100C
100C
120m
-0.8mm
or 0.08mm
Spdt
LAMPIRAN : 5 of 6K
EB
B P
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FOR
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acerText Box> 14.0Mpa -----> pump A STOP
< 10.5Mpa -----> pump A START
jika pressure masih rendah dari :
< 10.0MPa -----> pump B START ( 2 motor A & B START)
acerText Box
-
120m
120m
01505E TURBINE CONTROL 1.pdfCONFIGURATION OF CONTROL.pdf505E TURBINE CONTROL 2.pdfFREQ AND LOAD RELATIONSHIP.pdfPID1.pdfPID2.pdfMANUAL START.pdfSEMI AUTO START.pdf505E TURBINE CONTROL3.pdf
23dwg1.pdfdwg2.pdfdwg3.pdfdwg4.pdfdwg5.pdfdwg6.pdf