in the name of omnipotent - saba web pagesaba.kntu.ac.ir/eecd/people/dorosti/publications/dcs...

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In the Name Of Omnipotent

K.N.Toosi University Of TechnologyControl Engineering Department

Masoud Dorosti

Study of DCS Technologyor

Distributed Control SystemsBased On

TXP Power Plant Control System

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Automation

Factory Automation:Or Discrete Automation is to control a mechanism that function in ON/OFF mode or in 1 and 0 logic such as an automation in automobile factory.Solution of this automation is PLCs that is in function in industries since 1970s and control sequential tasks.Process Automation:Or Continuous Automation Means to control process variables in closed loops in order to reach to desired values. In process control we have multi loops.

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Introduction to Control Systems

Hierarchy of Control Systems:

Pneumatic (3-15 psi)

Electromechanical

Electrical (Analog) (4-20 mA)

Electrical (Digital)

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Introduction to Control Systems

Chronological of control systems in large scale plants:

LCS in 1960s

CCS(DDC) in 1970s

DCS in 1980s

FCS in 1990s

LCS: Locally Control SystemCCS: Centralized Control SystemDDC: Direct Digital ControlDCS: Distributed Control SystemFCS: Field Control System

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THE HIERARCHICAL STRUCTURE OF DCS

Operating andmonitoring level

Field level

Processing level

OTOT OTOT OTOT

AGF

APAP

S5-AG

S5 E/ASIM-TSIM-FFUM-F

AP

FUM-B

Group control level

PUPU ES680ES680 DS670DS670

AP

APTAPF

SIM-B

OT/ETOT/ET

CTCT675CT675AP

OT/DTOT/DT

Individualcontrol level

Plant busPlant bus

Terminal busTerminal bus

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Field bus control system

What is the field?Field is a place that some processes take place in it and

instruments & actuators such as control elements & valves & pumps & motors & transducers & etc is placed on it.

So What is the field bus?Field bus in general is a network that join control elements

together and to higher control systems such as PLCs & DCS. In other words Field bus is a bus that go through the field and go toward instruments & actuators.

In new field bus we have smart elements. instruments, transducers and actuators have digital processor on itself to perform a two-way communication with other elements and / or control itself

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What is Foundation field bus?Foundation field bus Is the name of a brand

such as Profibus and Devicenet.Foundation field bus and Profibus have the

same physical layer and work by rate of 31.25 kbps in the field

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A typical Field bus has following layers:

• Physical layer: instead of 4-20 mA analog signal• Data link layer: communication control between different

devices• Application layer: data converting understandable box for

other systems• User layer: perform a functional control block

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GAS TURBINE FUNDAMENTALS

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V94.3A COMBUSTION TURBINE

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The control of a Combustion Turbine is a very precise and complicated task. Some of the items that need to be precisely controlled are:

• Active power, • Reactive power, • Power factor, • Voltage, • Frequency, • Speed, • Torque, • Ramp rates, and • Temperature.

GAS TURBINE CONTROL FUNDAMENTALS

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PROCESS CONTROLA Gas Turbine is a process. The control of a Gas turbine is process control. We use different types of control schemes (Speed, Load)

Speed Loop ExampleSynchronization of Generator.

Goal - Match Frequency of Generator to Frequency of GridController changes speed of turbine to change the speed of the generator. Speed is Proportional to FrequencySpeed Change = Frequency Change

Position Loop ExampleFuel Control Valves. Change the position of a valve - Increase or Decrease Amount of FuelChange Flame Temp - Increases amount of Fuel - Flame will Become Hotter.Hotter Flame = Increase in Hot Gas Expansion Through TurbineIncrease in the Mass Flow through the Turbine.Increase in Either the speed or torque of the turbine.

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The mass flow through the turbine is increasingThe controller in the SES (static excitation system) is increasing the Field Current to the generator,• Field Current Increase = Increase in the Magnetic Field, which prevents

the speed from increasing. • The increased field and increased torque cause an increase in the amount

of current flow through the generator stator• End Result = Increase in Load (Active Power).

PROCESS CONTROL

What prevents the speed/frequency from increasing when the generator is on load?

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TURBINE CONTROL

Combustion turbines are controlled during all phases or modes ofits operation, from standstill through full load operations back to standstill. The 5 basic modes of control for a Combustion Turbine Generator are:

• SFC/SES Control• Speed Run Up• Speed Control• Load Control• Temperature Control

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BASIC TURBINE CONTROL

SFC/SES Control

Speed Run-up Controller Load Controller

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SFC/SES CONTROL

Initial Start Up Phase of the Turbine. • Controls the Generator As a Motor to Start the Combustion

Turbine.

From Standstill the SFC (Start-up Frequency Converter) Controls Turbine Speed By Energizing the Stator of the Generator.

The SES (Static Excitation System) Provides a Field to the Rotor of the Generator.

The SFC/SES Will Be the Sole Controller in Operation Until Approximately 11 s-1 (660 RPM) [@22% Speed].

At this point, the Gas Turbine Controller will activate the Speed Run-up Controller.

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SPEED RUN-UP FUNCTION

6 At ≈ 6.6 s-1 (396 RPM) [13% speed] - NG ESV is opened and the turbine is fired

6 CT is not capable of accelerating on its own.

6 SFC/SES will continue motoring the generator to assist in the acceleration.

6 At ≈ 22% speed (11 s-1) [660 rpm], the Speed Run-up Function will be activated.

6 The Speed Run Up Function & SFC/SES Work Together

!The Speed Run-up Controller Controls the Diffusion Control Valve to Increase

the Amount of Fuel to Ramp Up to Nominal Speed

!As the Speed Run Up Function slowly increases its control of the turbine

(increases the amount of fuel), the SFC/SES Control slowly decreases its

control (amount of torque supplied by the generator).

6 At ≈ 70% Speed (≈ 35 s-1) [≈ 2100 RPM] the SFC and SES are turned off

6 CT will continue to accelerate on its own.

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ActualSpeed

SpeedSetpoint 100%

Speed Run Upand Protection

FunctionLimiting Valve

ControllerEHC ElectroHydraulicConverter

6 Actual Turbine Speed Is Compared to a Speed Setpoint (100% or Nominal Speed).6 Output of the Speed Run-up Function Will Demand Greater Amounts of Fuel Within the Limits

of the Turbine Until the Actual Speed Approaches the Setpoint6 As Actual Speed Approaches Setpoint, the Output of the Speed Run up Function Decreases.6 Speed Run up Function Accelerates the Turbine to Nominal Speed!The Speed Run-up Controller Controls the Control Valves to Increase the Amount of Fuel

to Ramp Up to Nominal Speed!As the Speed Run Up Function Slowly Increases its control of the turbine (increases the

amount of fuel), the SFC/SES Control slowly decreases its control (amount of torque supplied by the generator).

6 Valve Controller Converts the Speed Run up Function Output to Analog Electric Signal. 6 EHC Electro Hydraulic Converter Converts the Electric Signal to a Hydraulic Signal

SPEED RUN-UP FUNCTION

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SPEED CONTROL

ActualSpeed

SpeedSetpoint 100%

Load/SpeedController Limiting Valve

ControllerEHC ElectroHydraulicConverter

SpeedSetpointControl

6 Controls the Amount of Fuel to the GT While Operating at or Near Synchronous Speed With the Generator Breaker Open.

6 Increases or Decreases Speed of the GT to Enable Synchronization of the Generator to the Grid.

6 The Gas Turbine Controller;!Activates the Speed/Load Controller in the Speed Control Mode for Synchronization,!Deactivates the Speed Run-up Controller,!Activates the Static Excitation System (SES) again

6 Synchronizing Unit Provides the Speed Setpoint Based on the Frequency of the Grid. !Speed can be Adjusted from 95% to 103%,

6 When Synchronizing Unit closes the Gen Breaker; !Gas Turbine Controller switches from Speed Control to Load Control!Load Controller Setpoint Output is set to 5 MW!Prevents Exhaust Gas Temperature Decrease!Reduces Thermal Stress of the Turbine

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LOAD CONTROL

The Load Control Mode Adjusts the Generated Load Based On the Load Setpoint and Other Conditions. Under Load Control, the SES Controller is Used to Generate and Change Load.

Load Control is more complicated than Speed Run-up or Speed Control.

At Any Time the Gas Turbine Controller Can Switch From Load Control to Speed Control or Temperature Control if Certain Conditions Occur.

Many Turbine Protection Functions Are Designed into the Gas Turbine Controller. They Can Prevent the Generator Load from Reaching the Load Setpoint.

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LOAD CONTROL

ActualLoad

Load/SpeedController

Limiting ValveController

EHC ElectroHydraulicConverter

Corrected OutletTemperature

Control

TemperatureSetpointControl

Base/PeakLoad Select

Fast/SlowGradient Select

Gradient

SetpointAdjuster

GeneratorLoad Limit

Manual LoadSetpoint

LoadSetpointControl

FrequencyInfluence

5 MW

Humming/AccelerationDetection

CorrectedOutlet

Temperature100 MW

Humming 1 =-6 MW

Humming 2 =-15 MW

Norm = 13 MW/minFast = 13 MW/minSlow= 7 MW/Min

13 MW/min

5, 18, 31, etc ~ 7 minto 100 MW

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TEMPERATURE LIMIT FUNCTION

TATK = Corrected Outlet Temp(TT.ATK.EGGLK) = 574°C

Temperature Control is the ultimate control of the turbine.

Controlling the exhaust temperature ensures that the temperature limitations of the combustion turbine are not exceeded.

SFC/SES Control

Speed Run-up Controller Load Controller

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FREQUENCY INFLUENCE

Allow a certain amount of fluctuation before attempting to correct the speed (frequency) of the combustion turbine.

Two different frequency functions are associated with combustion turbine control,

Frequency Limit FunctionAllows the speed of the generator to droop a total of +3/-5% (+90/-150 RPM) to stay synchronized. If the speed droop exceeds the limit, the generator breaker will open. The Frequency Limit Function is always active and cannot be disabled for normal operations.

Primary Frequency Influence FunctionWhen activated, will only allow the frequency to fluctuate 0.05Hz (3 RPM) before attempting to make a correction. This is a much tighter control of the frequency. Allows the Gas Turbine Controller to adjust the power output to compensate for the slightest frequency change; the maximum power output adjustment is limited to +/-75 MW from the setpoint. The generator breaker will open if this limit is exceeded.

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TXP CONTROL

The actual tasks of starting, stopping, controlling, monitoring,and protecting the turbine are controlled by the TXP AS620.

It would be impossible for anyone to operate the Combustion Turbine Generator by hand, there are way too many task that have to be carried out.

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SUB LOOP CONTROLLER “SLC”

• Turn Off Turning Gear• Turn On Lube Oil Pumps• Test Emergency DC Lube Oil Pump• Turn On Lift Oil Pump• Turn On Lube Oil Tank Vent Fan• Turn on the Hydraulic pumps• Open Inlet Air Damper• Open Blow Off Valves• Turn On SFC• Adjust Speed• Turn On Igniters

• Open Fuel Gas ESV• Adjust Fuel Gas Control Valve• Turn Off Lift Oil Pump• Turn Off SFC• Adjust Fuel Gas Control Valve• Close Blow Off Valves• Turn On SES• Adjust Voltage & Fuel Gas Control Valve• Turn On Synchronizer• Adjust Voltage & Fuel Gas Control Valve• Close Breaker• Adjust Load & Fuel Gas Control Valve

Sub Loop Controllers• Can be turned On or Off• When turned On,?Runs in a continues loop.?Constantly checking the status of a device or function.? If that status requires a specific action or task to be accomplished, the Sub Loop

Controller will carry out that action and continue monitoring the status for a change.Several Sub Loop Controllers are used in Combustion Turbine:

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Sends out a sequence of commands to devices and functions to perform a specific task, and waits to see if that task was accomplished in the required time.

• If not accomplished in the required time, the SGC MAY stop the whole process and begin the Shut Down Sequence.

• If accomplished, the SGC will proceed to the next sequence step to send out more commands.

Organized in steps, each step issues specific commands. A single step can issue one or more (and sometimes none) commands. Within that same step, there are tasks or statuses that the SGC needs to verify have been accomplished before proceeding to the next step, these are called permissives.

Typically, steps 1 through 50 are used for a Start Up Sequence, and steps 51 through 100 are used for a Shut Down Sequence.

SUB GROUP CONTROLLER “SGC”

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Sub Group Controllers are part of the AS620. Several Sub Group Controllers are used to control the Combustion Turbine:

• SGC Gas Turbine• SGC Lube & Lift Oil System• SGC Natural Gas• SGC Fuel Oil• etc.

SUB GROUP CONTROLLER “SGC”

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SGC STEP SEQUENCE EXAMPLESTEP 56WT = 2s

&

MKC01DE111VAR = 0 BALANCE

XS56ON

MBJ01DE103XS56SFC CMD OFF

2s/30s

S56

BAC01GS001GEN CB

XS57CMD OPEN

0s/5s

S57

≥1

MKC01DE307VAR=0

XG33VALID

MKY01EU010GENERATOR

ZV02N ON LD

CB MKC01DE111CMD ON

CB MBJO1DE1013CMB OFF

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GAS TURBINE INSTRUMENTATION

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GT INSTRUMENTATION

The Gas Turbine Instrumentation system monitors:

• Critical Combustion Turbine Parameters• Speed• Vibration• Temperature• Pressure Variables

• Compressor Inlet• Guide Vane Pitch Adjustment• Dryer Conditions

• Combustion Chamber Instrumentation• Pressure drop across the burners of combustion chambers• Acceleration - Humming• Flame-out conditions

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GT INSTRUMENTATION

• The combustion turbine instrumentation system can be divided into the following tasks:

• Combustion Turbine Speed Measurement • Combustion Turbine Casing Vibration Measurement • Combustion Turbine Shaft Vibration Measurement • Bearing Temperature Measurement • Compressor Inlet Guide Vane (IGV) Pitch Adjustment • Compressor Inlet Temperature Measurement • Compressor Inlet Pressure Measurement • Compressor Outlet Pressure and Temperature Measurement • Turbine Outlet Temperature Measurement • Combustion Turbine Intake Air Drying

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GT INSTRUMENTATION

C o m b u s t io nC h a m b e r C o n t r o l

C o m p . O u t le tP r e s s . a n d T e m p .

T u r b i n e O u tl e tT e m p .

C a s i n g V i b r a t io n

B e a r in g T e m p .

S h a f t V ib r a t io n

C o m p . I n le t T e m p .

C o m p . IG VA c t u a to r

B e a r i n g T e m p .

C a s in g V i b r a t i o na t io n V i b r a t io n

G T S p e e d

C o m p . I n le t P r e s s .

S h a f t V i b r a t io n

A i r D r y in g

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SPEED

Gas Turbine Speed Measurement

• Ensures the gas turbine operates within its designed range (95 to 103% of rated speed)

• May operate outside of these limits for a brief time only• Immediate trip if the gas turbine exceeds ~54 s-1 (3240

rpm), (108%) of rated speed• GT controller uses sensors for indication and for over

and under frequency protection.• Two redundant speed monitoring systems• Each system contains 3 channels• Both monitoring systems signals are forwarded to the

over speed protection system• Two channels of one speed monitoring system exceeds

108% of rated speed the turbine is tripped on over speed.

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SPEED

• The gas turbine CONTROLLER receives signals from ONEspeed monitoring system which receives signals from their speed sensors, MBA10CS101-103. This speed monitoring signal is used for the operation and control of the gas turbine. With the generator loaded (or not) the gas turbine will trip on over-under frequency if speed exceeds specific values for an extended period of time.

• If any 2 channels within a single speed monitoring system do not function properly, the gas turbine will immediately trip. If any 2 of the 3 channels of either set of signals to protection system do not function properly, the over speed protection system will trip. If at least 2 out of 3 speed signals from one of the speed monitoring systems indicate that the speed exceeds about 3,240rpm, the gas turbine will trip.

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SPEED

1. Speed Transmitter (MBA10CS101)2. Speed Transmitter (MBA10CS104)3. Speed Transmitter (MBA10CS102)4. Speed Transmitter (MBA10CS105)5. Speed Transmitter (MBA10CS103)6. Speed Transmitter (MBA10CS106)7. Intermediate Shaft8. Compressor Bearing9. Plug Connector10. Lower Bearing Seal

a. Groove in Intermediate Shaftb. Gap Between Shaft and Sensor

MBD12CY111 MBD12CY112

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CASING VIBRATIONOperating within the allowed vibration levels:• Minimizes stress and wear on components. • Prevents mechanical connections from loosening.• Helps to ensure steady–state operation.

Casing Vibration Sensors:• Measure vibration levels at the bearings since the bearings transmit vibrations from

the rotor to the casings. • Turbine Bearing Housing - MBD11CY101 and MBD11CY102.• Compressor Bearing Housing - MBD12CY101 and MBD12CY102• Each sensor signal is processed independently.• Signal–processing unit calculates the effective vibrational velocity and forwards it to

the combustion turbine controller.

“Alarm” Signal :• Any one sensor reports vibrations above 9.3 mm/s (0.37 in/s). “Trip” Signal :• Both sensors for a bearing report that the vibrations exceed 14.7 mm/s (0.58 in/s) OR• One sensor reports vibrations exceed the limit value 14.7 mm/s (0.58 in/s) and a fault

of the other sensor exists.

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CASING VIBRATION

CT Startup is NOT allowed if a Vibration Measuring Fault exists.

Sensor Calibration Condition must be checked occasionally:• During Normal Operation - Turn the “CAL” key lock switch to

Cal - Checks the sensor and circuit condition.• DO NOT Check during Startup, Shutdown, or Large Load

Changes• Sensor is removed from Circuit and “CAL ON” alarm is

issued.

“CAN FLT” or “FAULT”• Signals from sensors of same bearing deviate by more than

1.0 mm/s for > 3 seconds.• Processor Module recognizes a disturbance of the sensor

signal• Sensor Signal is Above or Below it’s Specified Range.

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CT CASING VIBRATION MEASUREMENT

MBD11CY112

MBD11CY111

MBD11CT101MBD11CT102

MBD11CY102MBD11CY101

MBD12CY101MBD12CY102

CompressorCasing Split

Compressor casing vibration

Turbine casing vibration

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SHAFT VIBRATIONShaft Vibration Caused by:• Shaft imbalances, alignment errors, compressor surges, combustion instabilities,

uneven compressor and turbine air flows and bearing instabilities

The Shaft Vibration Measuring System:• Recognizes shaft vibration changes• Monitors radial clearances (for unbalanced thermal condition, critical speed) and • Records kinetic overstress of the bearings.Shaft Vibration Sensors:• Turbine Bearing Housing - MBD11CY111 and MBD11CY112.• Compressor Bearing Housing - MBD12CY111 and MBD12CY112• Each pair of sensors is located in the same axial plane and they are offset by 90º from

each other. • Each sensor has a proximity sensor and a signal amplifier.• Proximity Probes generate a high–frequency electro–magnetic field that changes as

the distance between the shaft and the probe tip changes.• This change generates a variable output voltage that is routed to the signal amplifier• Processor module combines the output from both sensors to determine the maximum

shaft displacement

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CT SHAFT VIBRATION MEASUREMENT

MBD11CY112

MBD11CY111

MBD11CT101MBD11CT102

Compressor shaft vibration Turbine shaft vibration

MBD12CY111 MBD12CY112

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GT BRG VIB/TEMP PRT

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BEARING TEMPERATURE

• Compressor Bearing:• Thrust Bearing Generator End, MBD12CT102 and

MBD12CT103 (Double Element)• Thrust Bearing Turbine End, MBD12CT104 and

MBD12CT105 (Double Element)–2-out-of-3 Voting Group with one spare

• Compressor Journal Bearing, MBD12CT101 (Triple Element)

• Turbine Bearing:– Turbine Journal Bearing, MBD11CT101 and

MBD11CT102 (Triple Element)

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BEARING TEMPERATURE

MBD12CT101

MBD12CT102/103 MBD12CT104/105

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COMPRESSOR IGV

The inlet guide vanes (IGV’s) control the amount of air flowing through the compressor and turbine. Opening the inlet guide vanes (IGV’s) increases the amount of airflow. Closing the IGV’s decreases the amount of air flowing through the compressor and the turbine. The control system can maintain a constant fuel/air ratio by changing the fuel flow and airflow rates simultaneously. Maintaining a constant fuel/air ratio ensures that the corrected turbine outlet temperature (TATK) remains constant during load changes.

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COMPRESSOR IGV

The V94.3A IGV position can be varied between –10% (Fully closed) and110% (Fully Open)

During start–up, boiler purge and shutdown, the IGVs are positioned tofully closed.

When the rotor speed gets close to rated speed (~45 s-1, 2700 rpm), theIGV’s move to the ‘CLOSED’ position (~0%) to prevent compressor bladevibration problems.

When Corrected Turbine Outlet Temperature Reaches Its Setpoint,The IGV’s will commence opening towards their “Fully Open” position.

Increases the airflow through the compressor and turbine allowing the control system to continue to increase the amount of fuel while maintaining a constant corrected turbine outlet temperature.

When the IGV’s have reached their “Fully Open” position, any furtherincrease in load (fuel) will increase the corrected turbine outlettemperature.

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COMPRESSOR IGV

1. Adjusting Ring 2. Bearing 3. Stationary Blade Carrier I4. Pushrod Actuator 5. Actuator 6. Compressor Support7. Compressor Inlet Guide Vanes 8. Vane Connecting Rod 9. Lever

Closed: -10%Open: 110%

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COMPRESSOR INLET TEMPERATURE

Required to calculate the corrected turbine outlet temperature (TATK). Four dual–element RTD’s. One element from each RTD is used to calculate the average compressor inlet temperature. The other element is a spare.

MBA11CT101MBA11CT102MBA11CT103MBA11CT104

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COMPRESSOR INLET PRESSURE/SURGE DETECTION

Compressor Inlet Pressure (MBA11CP101) measures the vacuum in the vertical intake duct.

Three Differential pressure switch (MBA11CP001, 002, 003) measures the pressure difference between the vertical intake duct and the compressor inlet, immediately upstream of the IGVs.

At turbine speeds greater than 42 s-1 (2520 rpm), if the differential pressure decreases below a specific level (approximately 30 mbar, 0.435 psi) a turbine trip is initiated to prevent compressor surge.

Compressor surges can be caused by:

• Operating the combustion turbine too slowly without opening the blowoff valves,

• Throttling the compressor IGV’s,

• Sudden uncontrolled combustion of fuel,

• Excessive combustion chamber pressure.

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COMPRESSOR OUTLET PRESSURE / TEMPERATURE

PRESSURE –

• Indication of cooling air supply.

• Indication of relative combustion chamber pressure loss.

• Signal used for limit control of the compressor outlet pressure gradient.

Two pressure transmitters, MBA12CP101 and MBA12CP102, are located downstream from the compressor outlet.

TEMPERATURE –

• Indication and control of the compressor outlet temperature.

• Indication of the burner temperature during premix.

The compressor outlet temperature dual-element thermocouples, MBA12CT101, 102 and 103, are located downstream from the compressor outlet

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TURBINE OUTLET TEMPERATURE

Twenty-four triple–element thermocouples, MBA26CT101 through 124

Equally spaced around the exhaust diffuser circumference directly downstream from the turbine exhaust.

The Operator Terminal displays all 24 individual readings and the corrected turbine outlet temperature (TATK).

The temperature controller uses the average turbine outlet temperature to calculate the corrected turbine exhaust temperature (TATK).

The combustion turbine temperature controller uses the TATK to adjust the fuel flow to respond to changes of temperature and hence changes in combustion.

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TURBINE OUTLET TEMPERATUREThe TXP uses the –B22 and –B23 elements to protect against three abnormal temperature conditions:

• A high temperature over the entire combustion area, • A hot spot near one thermocouple, and • Cold streaks.

The TXP uses only six thermocouple to detect overall HIGH TEMPERATURE.• High Temperature “ALARM” - >620ºC • High Temperature “Trip” - >660ºC.

All 24 thermocouples are used to detect HOT SPOTS or burner failures.• Each thermocouple is compared to the average temperature.• Hot Spot warning “HS WARN” - Any temperature differs from the average by >30ºC. • Hot Spot Trip - Any temperature differs by more than 50ºC.

If one or more burners extinguish, COLD STREAKS can form in the exhaust gas flow.• The turbine temperature protection system issues a warning “WARN” if two

extinguished burners are detected. • It will generate an alarm “GT–S/D” and initiate a normal shutdown if three adjacent

burners extinguish. • If four adjacent or 2 groups of 3 adjacent burners extinguish, the turbine will trip.

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GT TEMP TURB OUTLET

GT TEMP TURB OUTLET

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GAS TURBINE INTAKE AIR DRYING• During standstill, dehumidifier MBA10AT001, protects moisture–sensitive

turbine components from prolonged exposure to high humidity, condensation, and corrosive environments.

• 2 hours after shutdown begins, the shutdown sequence will close the motor–operated air inlet duct shutoff damper MBL20AA001 and turn on the dehumidifier.

• The combustion turbine control system automatically switches the dehumidifier off before startup.

Dehumidifier

Control Panel

ReactivationBlower

ProcessBlower

ReactivationAir Filter

Heater

DesiccantWheelHeaterReactivation

Air FilterReactivationBlower

ProcessBlower

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COMBUSTION CHAMBER INSTRUMENTATION

Used to :• Detect the pressure drop across the

combustion chamber• Combustion process instability (humming)• Flameout.

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COMBUSTION CHAMBER INSTRUMENTATION

Combustion chamber measuring instruments are used to detect the pressure drop across the combustion chamber, combustion process instability (humming), flashback, and flameout. In order to insure proper combustion. the combustion chamber is monitored in several ways.

• Differential pressure transmitter MBM10CP101 monitor the pressure across the burners.

• Pressure transmitter MBA12CP101 measures the compressor discharge pressure.

• The control system uses these pressure measurements to determine if the combustion process is stable or if the combustion process is becoming unstable and a quick changeover from premix to diffusion mode is required.

• Two dynamic pressure transducers, MBM11CP102 and MBM21CP102 are used to detect humming.

• Two Accelerometers, MBM11CY401 and MBM11CY402 are used to detectCC acceleration

• Temperature and flame monitoring are used to detect individual burner failure.

• Thermocouples located at the axial twirlers of each burner are used to detect flashback.

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FLAME MONITORS

• Checks for presence of flames. And trips the turbine if there is no flame.

• Two monitoring systems– flame scanner– associated analog module– each scanner monitors a group of 7 burners– detect the radiation emitted by the flames– two photocells- a silicon cell and a lead–sulfide cell

sense flame radiation– cover a wave length range of approximately 350 –

2700 nm

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FLAME MONITORS

• During a gas turbine start, the flame monitoring system is activated approximately 9 seconds after an open command has been issued to the gas emergency stop valve. After an additional 3 seconds, the flame monitoring signal is released. If at this time the “flame on “ signal of at least one of the two monitoring systems is present, the startup sequence is may proceed.

• Hence, a gas turbine trip is only initiated if both flame monitors report that the flame intensity has dropped below the “flame off” limit for more than 1 second.

.

page ٦٣

MONITORING FLAME

MBM13CR101MBM13CR102 MBM13CR101

MBM13CR102

.

page ٦٤

HUMMING/ACCELERATION

• Gas turbines with hybrid burners may experience combustion instabilities manifested as elevated alternating pressure amplitudes in combustion chamber pressure, called combustion chamber humming. The alternating pressure amplitudes, or humming, causes vibrations to occur in the combustion chamber. These pressure changes must be quickly detected and eliminated to prevent a further rapid increase in alternating pressure amplitudes and the possible consequential damage to components of the combustion turbine.

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• Humming is detected by measuring the alternating pressure amplitudes of the combustion chamber pressure using the two dynamic pressure transducers MBM11CP101 and MBM11CP102 mounted on the turbine center casing. The two pressure transducers measure combustion chamber pressure fluctuations. A signal conditioning unit filters out other frequencies to give an output measure for each transducer as an effective value. Each effective value is sent to the TXP for monitoring purposes.

• Acceleration is detected by measuring the vibration of the combustion chamber using two (2) accelerometers, MBM10CY101 and MBM10CY102 mounted on the combustion chamber. The two accelerometers measure the vibration of the combustion chamber.

Limit Humming Setpoint Acceleration Setpoint

Limit 1 (GW1) 25 mbar 2.5 g

Limit 2 (GW2) 40 mbar 3 g

Limit 3 (GW3) 80 mbar 8 g

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Three limits are imposed associated with humming and acceleration,typical values are as follows:

> Limit 1 for 4 seconds the turbine output is rapidly reduced by 6 MW. If the limit is still exceeded the power is again reduced by 6 MW.

> Limit 2 for 1 second the gas turbine output is rapidly reduced by 15 MW. If the limit is still exceeded the power output is again reduced by 15 MW. In both cases if these power reductions do not mitigate the humming or acceleration the natural gas system is tripped resulting in a gas turbine trip.

If Limit 3 is exceeded the gas turbine is immediately tripped.

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IGNITION TRANSFORMERS AND IGNITORS

Ignition transformers, MBM12GT001 to ...024 provide high voltage to generate sparks at the igniters of the 24 burners.

During the startup sequence, low voltage is supplied to the transformers where it is transformed into 2 x 5000 V. The high voltage is used to generate a spark at the tip of the igniters MBM12AV001 to ...024. The sparks are required to ignite the diffusion gas during a startup on fuel gas.

.

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GT BURNER TEMP MON

GT BURNER TEMP MON

.

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TXP INTRODUCTION

.

page ٧٠

Introduction into TXP

TTelperm

uniXXpower PPlant

control system

.

page ٧١

Introduction into TXP

Teleperm XP (TXP) process control system provides all I&C facilities that are necessary for automating, handling, monitoring, and archiving processes (such as operational instrumentation and control systems of power plants)

The task of a process control system in TXP are distributed to different subsystems:

• OM650: Operating and Monitoring system• ES680: Engineering system• DS670: Diagnostic system• AS620: Automation system• SINEC H1: SIEMENS network communication system

.

page ٧٢

The structure of TXP

SIMATIC NET Industrial EthernetSIMATIC NET Industrial Ethernet

ES 680ES 680EngineeringEngineeringSystemSystem

OM 650OM 650Operation and Operation and Management Management

SystemSystem

DS 670DS 670DiagnosticsDiagnosticsSystemSystem

CT 675CT 675CommissioningCommissioningToolTool

AS 620AS 620AutomatioAutomationnSystemSystem

Modular - Several software modules work together,

Distributed - Tasks are ‘distributed’ across several pieces of hardware,

Function Oriented -Similar functions are grouped together.Module : component, unit, subsystem

Modular : made of standardized units which can be assembled in different ways

.

page ٧٣

THE CLEAR AND HIERARCHICAL STRUCTURE OF TXP

Operating andmonitoring level

Field level

Processing level

OTOT OTOT OTOT

AGF

APAP

S5-AG

S5 E/ASIM-TSIM-FFUM-F

AP

FUM-B

Group control level

PUPU ES680ES680 DS670DS670

AP

APTAPF

SIM-B

OT/ETOT/ET

CTCT675CT675AP

OT/DTOT/DT

Individualcontrol level

Plant busPlant bus


.

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TXP FUNCTIONS

Several Major Functions are required to accomplish the complex task of Power Plant Control.

.

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TXP FUNCTIONS

The OM650 process control and information system is the interface between the system and operator in the control room. This highly ergonomic window to the process enables the process to be centrally monitored and controlled. In addition the system provides all functions that are required for logging the process and for archiving the data.

The ES680 engineering system is the central configuration system of TXP. ES680 is used for configuring the AS620 automation system, the OM650 process control and information system, the SINEC H1 FO bus system, and the necessary hardware. ES680 centrally administers all configuration data.

The configuration of the AS functions and processing functions in OM is based on control system flow charts to VGB guidelines

.

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TXP FUNCTIONS

The DS670 diagnostic system is the tool that is used for monitoring and detecting malfunctions in the I&C components of TXP.

In the event of malfunction, the diagnostic system swiftly takes the user to the source of the fault and informs about cause and possible elimination of the fault

The network structure of the SINEC H1 bus system enables communication between the individual subsystems of the process control system. The bus system complies with the international standards and consequently offers the prerequisites of open communication.

.

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TXP FUNCTIONS in hierarchy structure

.

page ٧٨

AS620 Automation System

The AS620 subsystem performs the automation tasks of the industrial processes. The AS620 acquires measured values and states from the process, perform open and closed loop control functions, and transfers the resulting manipulated variable values, correction values, and command to the process.

The other subsystems employ the AS620 subsystem as the interface to the process. The AS620 transfers the commands from OM650 operator communication and visualization system to the process, reads information from process that is required by OM650, ES680, or DS670 and transfers this information to the upstream operator communication and visualization level.

.

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page ٨٠

AS620 B Automation System

The AS620 Automation System is divided to following subsystems:

AS620 B: basic system for general automation tasks, system and unit protection, closed loop control. Central structure or distributed arrangement using buses are both possible.

• FUM-B variant: in a central structure, FUM modules (function modules) are used for connecting the sensors and actuators of the process.

.

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AS620 B Automation System

• SIM-B variant: SIM modules (signal modules) enable a distributed structure to be set up (locally, in vicinity to the process). A bus connected the SIM modules with the central system components.

.

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AS620 Automation System

AS620 F: fail-safe for protection and control tasks that require TUV approval (e.g. burner control).

Single and fault-tolerant structures are both possible, including the variants with the fail-safe automation processor (APF) and the fail-safe programmable logic controller (AG-F).

• FUM-F variant: configuration with the fail-safe APF automation processor and the related FUM-F modules (fail-safe function modules)

• SIM-F variant: configuration with the AG-F programmable logic controller. This variant employs the SIMATIC S5 AG S5-115F programmable logic controller with SIM-F modules.

AS620 T: Turbine controller and other high-speed control tasks at the turbine unit.

Auxiliaries connection: signal exchange with the SIMATIC S5 units. The SIMATIC units contain the implementation of a complete automation task that is not configured via ES680.

.

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AP Automation Processor

The AP automation processor is the central component of the AS620 B and AS620 F automation systems. It is based on the powerful SIMATIC S5 CPU 948/948R. The hardware of the automation processor is based on SIMATIC S5 155U

The AS620 T employs a special automation processor, the APT(SIMADYN D), to solve high-speed automation tasks at the turbine unit.

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AS620T - FAST, CLOSED-LOOP CONTROL FOR TURBINES

Communication with OM650 is accomplished via the AP (AS620B)

Powerful SIMADYN processor for Fast Closed-Loop controls

• Position Control 6 ms in case of gas or steam turbines

• Fast Signal Conditioning (1 ms timestamp resolution)

1 of 2 redundancy design for closed loop controls

Plant busPlant bus

SIM TSIM T

APAP

SIM TSIM T

AP TAP T

OMOM ESES

.

page ٨٥

GAS TURBINE CONTROLLER

DESCRIPTIONThe functions of the gas turbine controller are performed in different parts of the automation system. The controller itself is the AS 620 T (SIMADYN D). The gas turbine controller also uses the AS 620 F for the turbine protection functions and the AS 620 B for the open-loop control of the turbine.

The gas turbine controller is connected directly to the plant bus. Communication between the controller and the operation and monitoring system or the other components of the automation system is accomplished by a function block in one of the automation processors of basic automation system (AS620B).

Operation and monitoring of the gas turbine controller is done from the Operation and Monitoring System (OM Screens).

.

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AS 620 F

Plant bus

Operation and Monitoring SystemOM 650

AS 620 TTurbine

Open - LoopControl

TurbineProtection

Gas Turbine Controller

InternalBus

Simadyn D

Plant

LiveSignal

AS 620 B

Function blockfor gas turbine

controllerCPUAPT "B"

CPUAPT "A”

GAS TURBINE CONTROLLER HARDWARE CONFIGURATION

.

page ٨٧

Synchronization with the Grid

Loading of the Turbine

Gas Turbine Controller

SIMADYN D

Digital automation systemfor

• fast closed-loop control and calculation• fast open-loop control and monitoring• fast report and record

Frequency Stabilization

Reliable Load Rejection toUnit Auxiliary Power Requirement

Ability to Ride Outa Load Rejection

Prevention of Thermal Overloadingof the Gas Turbine

Prevention of Overloadingof the Compressor

Low-Stress Startup andShutdown of the Turbine

GAS TURBINE CONTROLLER CONCEPT

.

page ٨٨

TYPICAL OM650 STRUCTURE WITH EXTERNAL GATEWAY

Comprised of:• Operator Terminals (OT)

– Man - Machine Interface– Up to 40 may be

connected to the Terminal Bus.

– Up to 4 screens attached to a single OT.

– Color and Alarm printers– Mouse driven (standard

keyboard optional)• Processor Unit(s)

– Information channel for man-machine interfaces.

– Plant Process ‘traffic cop’• Server Unit

– Support functions– Not required for process

control

ExternalExternal

PU/SUPU/SUPUPU ...

...


...

NetworkNetwork

Bridge/Bridge/GatewayGateway

Plant busPlant bus

1 . . . 41 . . . 4

OTOTOTOTOTOT

Barco/EOSBarco/EOS Barco/EOSBarco/EOS

1 . . . 41 . . . 4

Barco/EOSBarco/EOS

.

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.

page ٩٠

PROCESSING UNIT (PU) FUNCTIONS

The processing unit establishes the link between the automation system connected to the plant bus and the process control and management system connected to the terminal bus.

On configuration, I&C plant areas (automation systems) are assigned as function groups to a PU.

The PU can be implemented in a 1 of 2 redundancy, two PU’s identical in Hardware and Software.

A PU comprises the following HW components:• Pentium class mini-tower• NICs for connecting to the busses.• Standard graphics adapter for servicing monitor

connection.

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page ٩١

PROCESSING UNIT (PU) FUNCTIONS

The main tasks of a PU are:•Processing the communication between the OM and the AS for the associated plant areas.•Updating an image of the current values or states of the associated plant areas.•Storing all data changes (events) for the associated plant areas in a short-term archive.•Applying binary status information to logic circuits and obtaining all-encompassing status changes (common alarms, incident review documentation).•Performing process information functions.•Performing calculations•supplying the dynamic information for the Operating Terminals (output and updating of dynamic display information).

.

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SERVER UNIT (SU) FUNCTIONS

The Server Unit (SU) is responsible for the central functions of long-term archiving and logging as well as for supply descriptive data.The SU is only connected to the terminal bus via which the communication between the PU’s and OT’s is processed. At least one MOD is connected for exporting long term archive data.The SU is always implemented regardless of the number of PU’s used.

An SU comprises the following HW components:• Pentium class mini-tower• NIC for connecting to the Terminal Bus.• Standard graphics adapter for servicing monitor

connection.

The main tasks of the SU are:• Managing data descriptions planned on the ES 680 in a

central database. This information is used mainly by the MMI and log functions through out the terminal bus (administrative) network.

• Log functions.• Long-term Archiving with external data storage.

The SU can be implemented in a 1 of 2 redundancy, two SU’s identical in Hardware and Software.

.

page ٩٣

OTOTTerminal bus Terminal bus

PUPU

Plant bus Plant bus

ASAS

Short term archive Short term archive

Ring memoryRing memoryadjustableadjustable

500 000 signals 500 000 signals

Short term archive ofall data in the PU(signals, statuses,calculated values and alarms)Binary and analog

Storage capacity forall signals appr. 8 hours

Transfer of the data into the long term archive every 20 sec.

Design of the short termarchive organized in theRAM as a ring memory

DATA STORAGE WITH OM 650SHORT TERM ARCHIVE

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page ٩٤

SUSU


PUPU

Plant bus Plant bus

ASAS

Long term archive Long term archive Long term archive for alldata with same density as in the short term archive

harddisc

Storage capacity for allSignals approx. 8 days

Design of the long termarchive organized on theharddisc as a ring memory

Transfer of data to MOD

Direct access to all dataOn MOD

MODMODRing memoryRing memory

12 x 1012 x 1066 signalssignalsextendable extendable

Storage capacity on MODApprox. 16 days

DATA STORAGE WITH OM 650LONG TERM ARCHIVE

.

page ٩٥

DATA STORAGE WITH OM 650LONG TERM ARCHIVE USING JUKEBOX

SUSU


PUPU

Plant bus Plant bus

ASAS

Number of MOD`s:32 up to 200

Storage capacityfor all signalsappr. 1 to 8 years

Up to 2 MOD drivesfor simultaneouslyreading and writing

JukeboxJukebox

PC-PC-controlcontrol

123

200

...

JukeboxJukebox

30...

.

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PLANT DISPLAY HIERARCHY

00CJA00EJ001PLANT OVERVIEW

11MBY10EJ101GT11 OVERVIEW

12MBY10EJ10GT12 Overview …....

11MBP10EJ102GT11 NG SYSTEM

11MBA10EJ220GT11 AIR SYSTEM

11MBP10EJ202GT11 LUBE/LIFT SYSTEM

11MBY10EJ205GT11 HYDRAULIC SYST

VLV

Note: Number of diagram levelsNote: Number of diagram levelsis not limited. is not limited.

PLANT OVERVIEWHighest Level

DiagramFUNCTION AREAS

Second Level Diagrams

SYSTEM DISPLAYSThird Level Diagrams

...

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page ٩٧

PLANT DISPLAY (EXAMPLE)

Plant display headline

Plant displayDisplay selectionPictogramsAnalog valuesBinary values

.

page ٩٨

DISPLAY SCREEN STRUCTURE

Screen Header

Display Area

Screen Footer

.

page ٩٩

SCREEN HEADER

Current System Date and Time

Plant Pull-Down Menu Button

Plant Overview Display Button

Common Alarm Indicators (CAI)

Process Display Overview (Trends) Button

System Pull-Down Menu Button

Horizontal Hierarchy Display Menu Selection Button

Vertical Hierarchy Display Menu Selection Button

Alarm Sequence Display (ASD)

Display Title

.

page ١٠٠

SCREEN FOOTER

Return to previous display page(s)(1 to 50)

Go to LEFT Horizontally related display page

Go to HIGHER Vertically related display page

Go to RIGHT Horizontally related display page

Select Monitor for next display action

Acknowledge Alarms

Silence Audible Alarms (Opt)

Print Hardcopy of Screen

Online HTML Help Manual

.

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DISPLAY SELECTION KEY“ SHORT CUT NAVIGATION “

Plant display(Subarea)

.

page ١٠٢

Analog and Digital Signals flow from left to right, top to bottom.

The FUP can be made dynamic, showing live analog and digital signals, useful during troubleshooting and tuning

PROCESS SOLUTIONS ARE DESIGNED WITH THE ES680 AND THE YFR LOGIC DIAGRAMS (FUP)

OutputsOutputs

Signal flowSignal flow

InputsInputs

.

page ١٠٣

LOGIC DIAGRAM (NAVIGATION)

Signal finding through directlogic diagram navigation

>1

&

>1

&

OFF ON

Follow up diagram available

Follow updiagram not available

.

page ١٠٤

SYSTEM MENU (ONE COMMON CONFIGURATION)

LOGON/LOGOFF ButtonCommon/

Automatic Alarm

Acknowledge-mentButton

Fault Event List Button

Logs/Plots Button

Long Term Archive Button

Notepad Button

Parameter Change Button

Calculator Button

Printer Admin Button

Alarms Disabled / SignalsInhibited Button

List Current Rights Button

SYSTEM MenuPull Down

Button

.

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DYNAMIC PICTOGRAPHS

MValves &Dampers

TEXTFault/Status Indicators

Flame 0Numerical

1Pre-SelectionDeviceSwitch Over

Sub Loop Controller

23Sub Group Controller

Set PointController

Continuous Controller

Motor Pump Fan Heater Breaker

INDICATORS

COMPONENTS

CONTROLLERS

Trend Selection Key

Display Selection Key

KEYS

.

page ١٠٦

POP-UP WINDOW STRUCTURE

Window Extension #1 (Mini-ASD)

Window Extension #2

Relocation Bar

Acknowledge Alarms

Acknowledge Manual Tracking Alarms

Engage / Disengage

Logic Diagram

Detail Window

Notebook

Close Pop-Up Window

Execute Selected Command

Freely Configurable (from ES680)

Error Messages

Enable / Disable

Manual Tracking Alarms(Type O -12 max)

System type Alarms (12 max)

Point Identification

Operation and Display Area

.

page ١٠٧

OPERATION WINDOW

Events (Mini-ASD) Logic diagram

Detail window

Notebook

Enable/Coupling

Device Pictographimage

Command buttons

.

page ١٠٨

BLOCK / ENABLE BUTTON

Manual Command

buttons

Block/EnableManual Commands (Buttons)

Block

Enable

AOFF

AON

CBOFF

CBOFF

OMSLC

Block/EnableAutomatic Inputs

Block

Enable

Automatic inputs

.

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DRIVE CONTROL OPERATING WINDOW

Device Feedback:Off/Closed : white

On/Open : System Color

Other Components using thisOperating-Window

Heater

Fan

PumpBreaker

Damper

Off On Close Open

.

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DAMPER / ACTUATOR OPERATING WINDOW

Enable Pulse-Buttons

Close OpenStop

Pulse-Close

Pulse-Open

Actual Position

Other Components using thisOperating-Window

Actuator

.

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CONTROLLER OPERATING WINDOW “CONTROL VALVE”

Enable / Disable+

Coupling / Decoupling

Notebook

Actual Position

Controller Deviation

Pulse-Open

Pulse-Close

Automatic / ManualButton

Close Stop Open

.

page ١١٢

CONTINUOUS CONTROLLER

Also known as a Manual/Auto Station.

Function: (continuously) position a component to a desired position based on Manual input or Automatic comparison of a plant process actual value (AV) to a setpoint (SP)

Modes:Manual - Operator determines the

required VALVE position (Y).Auto (closed loop control) - TXP

positions valve to desired value (Y) based on SP-AV deviation (error signal).

.

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SETPOINT CONTROLLER

Also known as a Setpoint Station.

Function: (continuously) generate a setpoint (SP) for a plant process based on Manual input or Automatic evaluation of a plant process.

Modes:Manual (Internal Setpoint) - Operator

determines the required setpoint.Auto (External Setpoint) - TXP

automatically generates setpoint (SP) based on existing plant conditions. Operator unable to change setpoint.

.

page ١١٤

PID CONTROLLER

The PID Controller uses the Setpoint and Continuous Controllers to manipulate a plant component to control a plant process or actual plant value (PV) to match a desired value (SP).

Example:A Tank Level PID Controller - senses the tank level (AV), compares AV to a desired value (SP). If AV < SP then it will open the make-up control valve (Y) to admit more water to the tank, raising tank level (AV) to equal the desired level (SP).

Y

SPAV

PID Controller

.

page ١١٥

PID CONTROLLER - MODES OF OPERATION - MANUAL

MANUAL MODE - The continuous controller is in manual mode, setpoint controller mode is irrelevant.The operator must evaluate and respond to changes in AV. The operator controls the Y output via manipulation of buttons in the pop-up window. SP and AV have no effect on valve position (Y).

Y

SPAV

PID Controller

.

page ١١٦

PID CONTROLLER - MODES OF OPERATION - AUTOMATIC

AUTOMATIC MODE - The continuous controller is in automatic (closed loop) mode, setpoint controller is in manual mode.The operator enters his desired setpoint (SP) via the setpoint controller. The continuous controller compares SP and AV inputs, generates an error (deviation) signal. The error signal automatically adjusts the Y output to make the error signal equal to zero (SP=AV). Y

SPAV

PID Controller

.

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PID CONTROLLER - MODES OF OPERATION - CASCADE

CASCADE MODE - The continuous controller is in automatic (closed loop) mode, setpoint controller is in automatic (closed loop) mode.The operator is unable to adjust SP or Y. The setpoint controller’s output (SP) is automatically determined and adjusted based on plant conditions. As in Automatic Mode, the continuous controller compares SP and AV inputs, generates an error (deviation) signal. This error signal automatically adjusts the Y output to make the error signal equal to zero (SP=AV).

Y

SPAV

PID Controller

.

page ١١٨

SETPOINT OPERATING WINDOW

Decrease IncreaseStop Enable Pulse-Buttons

Pulse-Decrease

Pulse-Increase

Operation Limits

Actual Setpoint

Slider

.

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PID-CONTROLLER FUNCTION PLAN

A_Open/Close = Automatic Open/CloseR_Open/Close = Release Open/CloseS_Open/Close = Protection Open/Close

A_CON = Auto-ControlR_CON = Release ControlA_MAN = Auto ManualR_MAN = Release ManualRM_Open/Close = Checkback Open/CloseRM_CON/MAN = Checkback Auto/Manual

.

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SGC OPERATING WINDOW

Shutdown StartupSGCOn / Off

Waiting-Time

Monitoring-Time

Operator Guide ModeButton & Indicator

Step Branch

Go Next Step

Next Step

Actual Step(Step-Set)

Select StepJump to

selected Step

Other Components usingthis

Operating-WindowGC

.

page ١٢١

SGC FUNCTION PLAN

F_OPER/STIL = Flickering SU/SDA_OPER/STIL = AUTO SU/SDR_OPER/STIL = Release SU/SDSA_OPER/STIL = Protection SU/SDA_OFF/ON = Auto SGC OFF/ONSTEP OPER/STIL = SGC Steps SU/SDRM_OPER/STIL = Checkback SU/SDCB_RT = Checkback MonitoringCB_A_OFF/ON = Checkback SGC OFF/ON

.

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DS670:Alarm Sequence Display (ASD)

.

page ١٢٣

ALARM EVENT TYPES (PRIORITIES)

An arriving alarm of the event type A indicates that an alarm limit was exceeded.

An arriving alarm of the event type W indicates that a warning limit was exceeded

An arriving alarm of the event type T indicates that a tolerance limit was exceeded.

An arriving alarm of the event type F indicates that an individual function in the I&C system is faulty.

An arriving alarm of the event type O indicates that there is a Manual Operator Adjustment event thatoccurred.

An arriving alarm of the event type S indicates that there is a fault in the I&C system which affectsseveral functions (Super ordinate I&C)

An arriving alarm of the event type L indicates that a local fault has occurred.

An arriving alarm of the event type C indicates that a status has changed

An arriving alarm of the event type M indicates that a Maintenance Action is required.

.

page ١٢٤

ALARM HIERARCHY

Tracing the source of an Alarm.

Common Alarm Indicators in the Header signify that there is that type of Alarm somewhere in the plant.

Common Alarm Indicators in the Plant Menu signify in which Function Area that the type of Alarm is located.

.

page ١٢٥

ALARM HIERARCHY

Tracing the source of an Alarm.

Common Alarm Indicators on a System Display page shows which component or function is ALARMING.

Bar Graph Color shows the status of display indications.

.

page ١٢٦

ALARM SEQUENCE DISPLAY - FA OVERVIEW

Various Function Areas available to the Operator

Number of NEW Alarms processed by the FA.

Number of OLD Alarms processed by the FA.

Function Area Selection/DeselectionButton

.

page ١٢٧

ALARM SEQUENCE DISPLAY

Function Area Overview - Statuses of the entire plant ASD and the individual FA ASDs.

Alarm Display - Chronological listing of Alarm Events that have been recorded by the ASD.

• Up to 21 Alarm Events may be listed

• May be configured for Newest on Top or Newest on Bottom

.

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ALARM SEQUENCE DISPLAY - FA OVERVIEW

Go to First NEW (Unack) AlarmTotal number of NEW AlarmsGo to First OLD (Ack) AlarmTotal number of OLD AlarmsToggles on and off of the automatic

update of the ASD to display the most recent alarm on the page.

Disables the selected Alarm - only removes from ASD, not from archiving.

Alarm Event Display FiltersDisplay NEWEST Alarm Page Back in TimePage Forward in Time

.

page ١٢٩

ALARM EVENT DISPLAY LINE

CAI (Common Alarm Indicator) identifies the Event Type.

Function Identification Code (FID)

Signal Identification Code (SID)

FA Processing the Alarm

Alarm Text (as Defined in BDM module of OM650)

Alarm Status

Alarm Units

Month/Date/Time of Event

• MM.DD HH.MM.SS.mmm

.

page ١٣٠

ALARM SEQUENCE DISPLAY

Opens the Notepad Function.

Selection of alarm for individual or group alarm acknowledgement (use the Acknowledge Alarm Button at bottom of page).

Selection of alarm and activating the ‘disable’ button.

.

page ١٣١

ALARM ACKNOWLEDGEMENT

Acknowledge Alarms Button• Active only when ASD is being

displayed.• Will acknowledge the entire page of

displayed or selected alarms

Silence Audible Alarms Button - Active on every display page.

.

page ١٣٢

DISABLING AN ALARM

Select Desired ALARM.

Select ‘disable’ button to disable Alarm.

OR…….

.

page ١٣٣

DISABLING AN ALARM

Enter Search Criteria ended with *.

Leave remaining spaces blank.

Select SEARCHES button.

Select Desired ALARM.

Select Right Arrow to disable Alarm.

.

page ١٣٤

DISABLING AN ALARM

The disabled alarm is now listed in the disabled box.

.

page ١٣٥

SEARCHING FOR AND REENABLING AN ALARM

To Search for all disabled alarms, enter only * for the search mask.

Select on SEARCHES button to search for disabled alarms and inhibited signals.

Select desired alarm,Select left arrow button to re enable the

alarm

.

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PROCESS DISPLAY IN OM650“ON-LINE TRENDS”

.

page ١٣٧

Process Overview Key

PROCESS OVERVIEW DISPLAY (TREND MENU)

.

page ١٣٨

PROCESS DISPLAYS IN THE OM650

Pre-Configured and Configurable Trends• Value vs Time• Bar Chart• X vs Y

Up to 10 points displayed in Value vsTime trend, both analog and digital.

10 definable time and value ranges, default ranges:

• 0-1 hr• 0% to 100%

.

page ١٣٩

TIME SCALE KEY SET

Increase Time Range

Decrease Time Range

Dynamic/Static Flow Key

Absolute/Relative

Time KeyMove Time

Range RightSelect Date

Key

Move TimeRange Left

.

page ١٤٠

Increase ValueRange

Move ValueRange Up

Select Default

SettingsMove Value

Range Down

DecreaseValue Range

VALUE RANGE KEY SET

.

page ١٤١

Value At Curve Start

Parameter Key

Plant ID Code

Plant ID Text

Lower Limit

Value At Cursor

Upper Limit Units

LEGEND

.

page ١٤٢

Configure

Key

Configure

Window

CURVE CONFIGURE WINDOW

.

page ١٤٣

Configure KKSKey

KKS Configure Window

Function ID (KKS)

Signal Text

CONFIGURE KKS

.

page ١٤٤

PROCESS DISPLAYS IN OM650 - BAR CHARTS

Bar Chart Displays -• Limit value indications• Colorized status indications• Real Time Values

.

page ١٤٥

ES680: LOGIC/CONTROL OPERATION AND APPLICATIONS

.

page ١٤٦

I&C DOCUMENTATION OVERVIEW

Function-oriented documentation is important to the power plant operator.

The control schemes are described on functional (or logic) diagrams.

Function diagrams are simplified representations which represent the logical circuitry used for the safety, control, processing and monitoring of the power plant.

Function diagrams illustrate the processing of:– Sequencing signals (start-up and shutdown

programs)– Protection signals (alarm and trip)– Supervision signals

.

page ١٤٧

Modular Concept

Each module (which may consist of several pages) represents the logical circuitry of a functional assembly.

Each module is designed to be used with other functional assemblies.

Each modular diagram:– Defines the operator inputs,– Defines the inputs from other functional

assemblies, – Shows how these inputs are integrated, – Performs functions, – Provides outputs that are routed to other functional

assemblies.

.

page ١٤٨

MODULAR CONCEPT

Function diagrams identify: – The operating permissives for devices (motor,

valve, etc.),– The operating permissives for subsystems (lube oil,

turning gear, etc.),– The operating permissives for the power plant.– The conditions required before starting the gas

turbine (Ready to Start).– The operations that must be completed from one

command step before proceeding to the next step.– The conditions that will initiate a turbine trip.

.

page ١٤٩

KRAFTWERKKENNZEICHENSYSTEM

ORPOWER PLANT

IDENTIFICATION SYSTEM

.

page ١٥٠

• Process-related identification: Identification of systems and items of equipment according to their functions in mechanical, civil, electrical and I&C (Instrumentation and Control) engineering.

•Topographic Mounting location identification:Identification of mounting locations of electrical and I&C equipment in Mounting units such as cabinets, panels and consoles.

•Location identification: Identification of topographic allocations in structures, floors, rooms and enclosures.

.

page ١٥١

KKS – PROCESS RELATED CODES

lFunction Identification Code (FID) – the unique identification of a component or Function Plan (Logic).

11MBY10CS901.XQ01

lSignal Identification Code (SID) – the unique identification of a signal defined on a Function Plan.

.

page ١٥٢

KKS – PROCESS RELATED CODES

1 2

A N

MBP 00113 AA X -S 01 Typical KKS Number

Component Serial No.

N = Number, A = CharacterAAA NN AA NNN A -A NN

Component Identification CodeEquipment Redundancy (Optional)Equipment Serial No.Equipment Identification CodeSystem Area Serial No.System Identification CodeUnit CodePlant Code

.

page ١٥٣

KKS – PROCESS RELATED CODES – FUNCTION ID

1 2

A N


Component Serial No.Component Identification CodeEquipment Redundancy (Optional)Equipment Serial No.Equipment Identification CodeSystem Area Serial No.System Identification CodeUnit CodePlant Code

N = Number, A = CharacterAAA NN AA NNN A -A NN

PLANT/UNIT CODE UNIT

00 STATION

10 GENERATING UNIT #1, COMMON SYSTEMS

11 GENERATING UNIT #1, GAS TURBINE #1


20 GENERATING UNIT #2, COMMON SYSTEMS



l Plant Code identifies largest grouping of plant equipment. The plant can include multiple generating sets and common systems.

l Unit Code identifies the specific generating unit within the plant.

l A four engine simple cycle site may have a Plant/Unit Code breakdown as shown below.

.

page ١٥٤


1 2

A N



N = Number, A = CharacterAAA NN AA NNN A -A NNl The System ID code is a three letter code

used to identify systems that comprise the power plant.

l The first letter designates major systems or functions and includes:

l M – Main Machine Set

l H – Steam Generating

l E – Fuel delivery

l L – Steam?Water/Gas Cycles

l The second letter identifies the sub group of the major system. Some examples:

l MA – Steam Turbine

l MB – Gas Turbine

l HA – Pressure Systems, both Steam and feedwater.

l The third letter designates the individual system.

l M – Main Machine, B – Gas Turbine, P – Fuel Supply, Gas

.

page ١٥٥


1 2

A N



N = Number, A = CharacterAAA NN AA NNN A -A NNl System area serial number. Assigned to

system areas, normally increasing with direction of flow.

l Equipment ID code. Identifies the type of component:

l The first letter identifies the component group type: A or B – Mechanical Equipment, C – Direct Measuring circuit, D - Closed Loop Control, etc.

l The second letter identifies the specific component type: AA –Valve/Dampers/etc, AP – Pumps, CE –Electrical Measurement, CF – Flow Measurement, CP – Pressure Measurement, etc.

l Equipment Serial (Sequence) Number. Used to identify the particular component and it’s function. See KKS chapter for examples.

.

page ١٥٦


1 2

A N



N = Number, A = CharacterAAA NN AA NNN A -A NNl Equipment Redundancy and Component ID –

Optional designation of smaller units on or within a component. Such as a valve’s open or closed limit switches.

l Component Serial Number – unique serial number for smaller units.

.

page ١٥٧

KKS – PROCESS RELATED CODES – SIGNAL ID

l Signal ID Code (SID) identifies a particular signal on a Function Plan (as given by the FID)l First letter identifies the usage of the signal (Origin refers to the source of the signal, Application refers to the destination of

the signal).l X – Identification for an individual signal origin.l Z – Identification for a gated (or composite) signal origin.l Y – Identification for a Signal Application (destination). A signal can have several applications.

l Second letter identifies the type of signal:l XQ – Analog signalsl ZQ – Analog signal that has been modified – an XQ turbine speed in RPM converted to a ZQ turbine speed in Hz.l XS – Functional Group Control step signalsl XH - Binary Limit Signal that is derived from an Analog Process signal.l ZV – Signal Gating, such as protective or alarm logic signalsl YP – Supervisory Control Destination, such as the Alarm Processing Area of the OM650.

l Last two numbers are the serialized identification of the unique signals.l There are more rules and specific definitions for SID’s when using function blocks. See KKS definitions for specific rules.

For example:l XA41 and XA42 are the “Checkback On” and “Checkback Off” signals from a SLC.l XB01 is the DCM command signal to turn on (or open) a pump (valve).

11MBY10CS901.XQ01

.

page ١٥٨

TXP LOGIC OVERVIEW

• Functional Plan (FUP) documentation is important to the power plant operator and is part of the technical plant documentation.

• FUPs allow the operator to fully understand the control of the plant components.

.

page ١٥٩

TXP LOGIC OVERVIEW

Function diagrams are a type of functional plan. (YFRs)

Function diagrams are simplified representations which represent the logical circuitry used for the safety, control, processing and monitoring of the power plant.

.

page ١٦٠

TXP LOGIC OVERVIEW

Function diagrams identify: – The operating permissives for individual devices

(e.g. motor, valve, etc.), for subsystems (e.g. lube oil, turning gear, etc.), and for the power plant.

– The conditions required before starting the turbine (Ready to Start).

– The operations that must be completed from one command step before proceeding to the next step.

– The conditions that will initiate a turbine trip.

.

page ١٦١

TXP LOGIC OVERVIEW

Organized in a hierarchicalstructure.

• overview level (YFH)• area level (YFM)• single-loop level (YFR). Each level of the hierarchy

represents diagrams of greater detail.

OverviewLevel(YFH)

AreaLevel(YFM)

IndividualLevel(YFR)

.

page ١٦٢

TXP LOGIC OVERVIEW

• YFR is subdivided into three sections; inputs, functions and outputs.

Presentationof Functions

Tabulator Section

Text Field

Tabulator Section

Signal OutputsSignal Inputs

.

page ١٦٣

TXP LOGIC OVERVIEW

XB02off

XA21equi1 onXS53

XH54OPTDXH03HIHI

DB 93D 208.1

SIGDEFSIGDEF

XB01/Z1

XB02/Z1

> 1

&

&

10 s 0

XA01/2

-

1

XB95/Z1

OM

PON

ENON

OON

channel 1

1

BLAP

OOFF

ENOFF

POFF

CBOFF

DCMmotor/solenoid valve

CBON

OM

DB 90D 17.0

DB 90D 15.15

DB 90D 15.12

DB 90D 15.13

7 0PGC40 EE001AUX CW PMPS

ZV01

XH04NOT LO

XH01on

DB 90D 1.11

DB 93D 114.1

DB 90D 15.9

7 0LAC11 CP001EFP A OIL P

7 0LAC20 AP001EFP B MTR

7 0LAC20 AP001EFP B MTR

7 0LAC00 EC001EFP A & B7 0LAB00 EC001Feedwater System

7 0LAB41 CP901EFP A NPSH PROTECTION7 0LAC10 CT001EFP A MTR NDE BRG T

XB95 SIGDEFEFP A MTR

SignalFlowInputs

Outputs

.

page ١٦٤

TXP LOGIC OVERVIEW

• The Diagram Information provides:– Title and purpose of the function diagram

• Designation of affiliation, (noun name)• Function Group, and• Function Chain (CT)

– Document Type• YFH - Overview Level Function Diagrams• YFM – Area Level Function Diagrams• YFR - Single-Loop Level Function Diagrams

– Affiliation - KKS– Sequentially Numbered Section

• Diagram Section • Page Numbering

.

page ١٦٥

TXP LOGIC OVERVIEW

Designation of affiliation

5Page 1

B001= 11MBV21AP001YFRFC GTYGTA00

Stat. Modification Date Name Stand. Orig./Repl.f/Repl. byCheckDrawn

GAS TURBINE SIMULATORTRAINING CENTEROFFENBACH

Date

MAIN LUBE OIL PUMP

Function Group

PROJECT INFORMATION DIAGRAM INFORMATION

Function ChainDocument Type

Affiliation

Siemens AGFunctional diagram individual level Sh.

.

page ١٦٦

TXP LOGIC OVERVIEW

• On the input signal side each signal provides;– KKS (12MBV20CT003B),– FGC (XMBV00)– Designation (Lube Oil Supply Temp #2), – Signal Identification (XQ01)– Setting (0 to 250)– Unit of measure (C)

.

page ١٦٧

TXP LOGIC OVERVIEW

• On the signal output side each signal provides;– Signal Identification (ZQ01)– KKS (12MBX71AA183),– Designation (Lube Cooler Temp Control Valve),– Setting (0 to 250)– Unit of measure (C)

.

page ١٦٨

TXP LOGIC OVERVIEW

Tracing signals within a single process-related identification area.

Siemens AG SLC OIL CIRCULATIONFUNCTION CHART

YFR = MBV21EE010

XN02SLC OIL CIRCULATION

CKAA01GK300PRINTER

T003

S02 N OFFK YP50

Sh.No.

&

1

Signalfrom

page no.

Connector

B / T001

“B” - Connector (like signal name), “T001” - Page number (where signal came from)

.

page ١٦٩

TXP LOGIC OVERVIEWTracing signals within

a single process-related identification area.


YFR = MBV21EE010

XA42SLC OIL CIRCULATION

SLC OIL CIRCULATION

MYB01EC001

MBV21EU002U001

M003SGC GAS TURBINE

T001

OFFYV

YV

Sh.No.

Signalto

page no.Connector

B / T003

“B” - Connector (like signal name), “T003” - Page number (where signal is going to)

.

page ١٧٠

TXP LOGIC OVERVIEWTracing signal connections between different process-related identificationareas.


YFR = MBV21EE010

XA42SLC OIL CIRCULATION

Signal name:MBV21EE0101-XA42SLC OIL CIRCULATION - OFF

Connected to:MYB01EC001 - page M003SGC GAS TURBINE

Name of this page:MBV21EE010 page T001SLC OIL CIRCULATION

SLC OIL CIRCULATION

MYB01EC001

MBV21EU002U001

M003SGC GAS TURBINE

T001

OFF

YV

Sh.No.

.

page ١٧١

TXP LOGIC OVERVIEWTracing signal

connections between different process-related identification areas..

Siemens AG SGC GAS TURBINEFUNCTION CHART

YFR = MYB01EC001 M003

Sh.No.

MBV21EE010SLC OIL CIRCULATION

XA42OFF

T001

AD / M004

> 1

Name of this page:MYB01EC001 page M003SGC GAS TURBINE

Signal from:MBV21EE010 XA42 pageT001SLC OIL CIRCULATION - OFF

.

page ١٧٢

GATE LOGIC

Gate logic is used to perform basic process and algebraic functions on signals.

.

page ١٧٣

BINARY VS. ANALOG SIGNALS EXAMPLES

Binary

OpenClosedEtcEtcLowHighNoYes

De-energizedEnergizedOffOn

CloseOpenFalseTrue

01

15 mV340 mm4.6 mA160 bar

88°C93%

40.3 MW

Analog

.

page ١٧٤

SIGNAL FLOW PATHS

Signal Crossing(no connection)

Signal Name

Signal Outputs or

Signal Branch

Signal Inputs or or

Same Input Signal to 3 Different Inputs

.

page ١٧٥

AND GATE

• An AND gate is a binary device whose output is defined by a truth table. The output signal is logic "1" when all input signals are logic "1". If any input is 0, the output is 0.

& 00

1

0

01

0001

11

A

AInputs Output

BB C

C

.

page ١٧٦

OR GATE

• An OR gate is a binary device whose output is defined by a truth table. The output signal is logic "1" if any input signals are logic "1". If allinputs are 0, the output is 0.

>1 00

1

0

01

0111

11

A

AInputs Output

BB C

C

.

page ١٧٧

EXCLUSIVE OR GATE

• An Exclusive OR gate is a binary device whose output is defined by a truth table. The output signal is logic "1" if and only if one input signal is a logic "1". If all inputs are 0, or more than 1 input is a logic “1” the output is 0.

.

page ١٧٨

NOT GATE - NEGATION

• A NOT gate (sometimes called a Negator) is a binary device whose output is the inverse of the input. The output signal is logic "1" when input signals is logic "0".

1 or

11

00

(0)(0)

(1)(1)

.

page ١٧٩

Sub Loop Controller

• A Sub Loop Controller is used to keep defined process states. Functions like a RS flip flop.

• Automatic controls can “block” operator input by placing a “1” on BLOM input

• Priorities are:– Automatic “OFF”– Automatic “ON”– Manual “ON/OFF”

SLC

AON

OM

CBON

CBOFF

AOFF

BLOM

.

page ١٨٠

SUB LOOP CONTROLLER

.

page ١٨١

SUB LOOP CONTROLLER

SLC

AON

OM

CBON

CBOFF

AOFF

BLOM

INPUT SIGNALS:

OUTPUT SIGNALS:CB-OFF -Checkback off

A-ON -Automatic on

CB-ON -Checkback on

A-OFF -Automatic off

OTHER SIGNALS:OM -Operating / Monitoring

BLOM -Block OM

.

page ١٨٢

DRIVE CONTROL MODULE

• The Drive Control Module (DCM) and associated SIM module are used by the AS 620B to carry out the drive control function for a motor or solenoid.

• Precedence:– Protection Off– Protection On– Auto Off– Auto On

DCM

AON

AOFF

ENOFF

ENON

PON

POFF

OM

CBOFF

CBON

BLOM

.

page ١٨٣


Execute Close

Notebook

Selection/Deselectionof Window Extension 2

Open theDetail Window

Function DiagramSelection 1

Enable

Disenable

Selection of Window Extension 1

MAIN LUBE OIL PUMPMBV21AP001

0 1

M

.

page ١٨٤


P-OFF -Protection off

A-ON -Automatic on

EN-OFF -Release off

EN-ON -Release on

A-OFF -Automatic off

P-ON -Protection on

CB-OFF -Checkback offCB-ON -Checkback on


BLOM -Block OMBLAP -Block AP

DCM

AON

AOFF

ENOFF

ENON

PON

POFF

OM

CBOFF

CBON

BLOM BLAP

.

page ١٨٥

DRIVE CONTROL MODULEAuto Off

DCM

AON

AOFF

ENOFF

ENON

PON

POFF

OM

CBOFF

CBON

1

0 11 X 0X

0

X means it does not matter if it is a 1 or 0

.

page ١٨٦


Protection Off

DCM

AON

AOFF

ENOFF

ENON

PON

POFF

OM

CBOFF

CBON

1

1 XX X XX

0


.

page ١٨٧


Auto On

DCM

AON

AOFF

ENOFF

ENON

PON

POFF

OM

CBOFF

CBON

0 1

0 01 1 01


.

page ١٨٨


Protection On

DCM

AON

AOFF

ENOFF

ENON

PON

POFF

OM

CBOFF

CBON

0

0 XX X 1X

1X means it does not matter if it is a 1 or 0

.

page ١٨٩


.

page ١٩٠

SUB GROUP CONTROLLER (SGC)

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

• The Sub Group Controller (SGC) is used to automate large processes such as:

– System or Turbine Startups– System or Turbine Shutdowns– System Test functions

.

page ١٩١

SUB GROUP CONTROLLER (SGC)

SGC

.

page ١٩٢

SUB GROUP CONTROLLER

INPUT SIGNALS: OUTPUT SIGNALS:

A-STILCB-STIL

SDA-STIL STEP-STIL

CB-A-ON-Automatic com. standstill

-Checkback standstill-Protection com. standstill -to 1st step standstill

-Checkback SGC-On

A-ON -Automatic com. SGC-On

CB-STILCB-RTA

EN-STIL PROG-STIL

CB-A-OFF-Checkback standstill

-Checkback monitoring time-Enabling standstill -Program memory standstill

-Checkback SGC-Off

CB-OPER

EN-OPER

PROG-OPER-Checkback operation

-Enabling operation

-Program memory operation

A-OFF -Automatic com. SGC-Off

A-OPER

CB-OPER

SDA-OPER

STEP-OPER-Automatic com. operation

-Checkback operation

-Protection com. operation

-to 1st Step operation


SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ١٩٣


.

page ١٩٤


SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

• STIL - Standstill : Initiates standstill program

• OPER - Operation : Initiates Operation Program

.

page ١٩٥


SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

• A/ON - The automatic function of SGC is switched on by logic allowing automatic control of SGC.

• A/OFF - The automatic function of SGC is switched off by logic preventing automatic control of SGC.

.

page ١٩٦


• CB A/ON - The automatic function of SGC has been switched on by logic allowing automatic control of SGC.

• CB A/OFF - The automatic function of SGC has been switched off by logic preventing automatic control of SGC.

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ١٩٧


Very similar to DCM off control.• EN STIL - Start enable for operating direction “Standstill”

• A STIL - Operating direction “Standstill” has been selected by logic

• SDA STIL (Status Discrepancy Alarm) - Operating direction “Standstill” has been selected by protection logic

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ١٩٨


SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

• STEP STIL - Start signal for operating direction “Standstill” to begin step 51

• PROG STIL - Steps in the operating direction “Standstill” are in progress

.

page ١٩٩


• CB STIL (Input)- Checkback signal from logic• CB STIL (Output)- Indicates a checkback signal

from logic has been received

• CB RTA - A step in the selected operating direction has exceeded it’s monitoring time.

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ٢٠٠


Very similar to DCM on control.• EN OPER - Start enable for operating direction “Operation”

• A OPER - Operating direction “Operation” has been selected by logic

• SDA OPER (Status Discrepancy Alarm) -Operating direction “Operation” has been selected by protection logic

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ٢٠١


• STEP OPER - Start signal for operating direction “Operation” to begin step 1

• PROG OPER - Steps in the operating direction “Operation” are in progress

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ٢٠٢


• CB OPER (Input)- Checkback signal from logic• CB OPER (Output)- Indicates a checkback signal

from logic has been received• CB RTA - A step in the selected operating direction

has exceeded it’s monitoring time. Same output used for both operating directions

SGC

AOPER

ENOPER

OM

SDAOPER

CBOPER

ASTIL

ENSTIL

AOFF

CBSTIL

SDASTIL

AON

PROGSTIL

CBSTIL

STEPSTIL

CBON

STEPOPER

PROGOPER

CBOPER

CB AOFF

CBRTA

.

page ٢٠٣

SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput

&Mo - TimeWaiting timeStep No.tue: 25stw: 20s51 1

Command

ToFollow-on Logic

• The individual steps of a subgroup control are each programmed in individual blocks called step/program blocks.

• Step/program blocks include step number, wait times, monitoring times, enabling steps and commands.

.

page ٢٠٤

SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput


Command

ToFollow-on Logic

• Step numbers tell the operator what step of the program the SGC is on.

• In general, steps 1 - 50 are used for the operation direction (startups) and steps 51 - 99 are used for the standstill direction (shutdown)

.

page ٢٠٥

SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput


Command

ToFollow-on Logic

• The inputs are called step enabling conditions• To start this step either,

– the previous step must be completed AND the previous logic satisfied

– OR the alternate bypass logic must be satisfied

.

page ٢٠٦

SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput


Command

ToFollow-on Logic

• When the step enabling criteria are met, the step block first looks at the follow-on logic for the next step.

• If the follow-on logic is satisfied prior to the step being executed, this step is skipped (Command output remains a 0) and a 1 is placed on the next step output.

.

page ٢٠٧

SGC STEP SYMBOL

Previous logic satisfied Step 3 complete

.

page ٢٠٨

SGC STEP SYMBOL

If this logic is satisfied priorto sending command output from step 4, step 4 is skipped.

.

page ٢٠٩

SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput


Command

ToFollow-on Logic

• If the enabling criteria is satisfied and the follow-on logic is not satisfied, a 1 is placed on the command output.

• When the next step is executed, the 1 is replaced with a 0.

.

page ٢١٠

SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput


Command

ToFollow-on Logic

• Immediately after sending out the command step, a 1 is placed on the output to the next step.

• When the next step is executed, the 1 is replaced with a 0.

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SGC STEP SYMBOL

AlternativeBypass

FromPrevious Logic

From Previous Step

ToNext Step

CommandOutput


Command

ToFollow-on Logic

• Both the wait and monitoring time begins when the enabling criteria are satisfied.

• Following the wait time (here 20s) a 1 is placed on the output to the follow-on logic.

• If the next step is not entered prior to the monitoring time, the SGC is considered “blocked” at this step and an error message is sent to the TXP OM station.

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SGC STEP SYMBOL

Let’s walk through a complete step.

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RS FLIP FLOP

• A flip flop is a Digital memory device whose output states are as defined in a truth table.

• They have Binary inputs R and S.• They can have Binary outputs Q and Q not. • Note the Q is always associated with the S

and the Q Not is associated with the R.

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RS FLIP FLOP - RESET

• A flip flop is a binary memory device whose output states are as defined in a truth table. “S” in the truth table indicates that the output remains in the same or previous state.

• “Reset Sensitive” or “Reset Override” is the preferred state.

00

1

0

01

S010

11

SInputs Outputs

R Q QS10

R S

Q Q

Set

Reset

QQ NOT

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RS FLIP FLOP - SET

• A flip flop is a binary memory device whose output states are as defined in a truth table. “S” in the truth table indicates that the output remains in the same or previous state.

• “Set Sensitive” or “Set Override” is the preferred state.

S R

Q Q

Set

Reset

QQ NOT

00

1

0

01

S011

11

SInputs Outputs

R Q QS1

00

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RS FLIP FLOP

• This gate works the same as the previous Flip Flop.

• Note the Q is always associated with the S and the Q Not is associated with the R.

R S

Q Q

Set

Reset

QQ NOT

00

1

0

01

S011

11

SInputs Outputs

R Q QS100

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SUB LOOP CONTROLLER

SLC

AON

OM

CBON

CBOFF

AOFF

00

1

0

01

S010

11

Inputs Outputs

Off

S10

Off

BLOM

• A Sub Loop Controller is used to keep defined process states. Functions like a RS flip flop.

• Automatic controls can “block” operator input by placing a “1” on BLOM input

• Priorities are:– Automatic “OFF”– Automatic “ON”– Manual “ON/OFF”

On On

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SUB LOOP CONTROLLER

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&

>1 >1

&

POFF

ENOFF

AOFF

AON

ENON

PON

CBOFF

CBON

R S

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PULSE GENERATORS & TIME DELAYS

• Time Delay On – output is a logical 0 anytime the input is 0– When the input becomes a logic 1, the output will

change to a logic 1 only after the time designated (2 sec in the example) has passed. The output will remain in the logic 1 state as long as a logic 1 remains at its input

– If the input changes back to 0 before the time delay expires, the output never changes

– When the input changes from 1 to 0, there is no delay in the output changing to 0.

Note: For a TD on, the designated time (2) is on the left and the units (s) are in the middle.

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Time Delay On

0 1 2 3 4 5 6 7 8 9 10 time [s]

0 1 2 3 4 5 6 7 8 9 10 time [s]

2s2 0

Output

Input

s

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Time Delay Off (Sequence Timer Off Delay)• A time delay Off

– output is a logical 1 anytime the input is 1– When the input becomes a logical 0, the output becomes a

logical 0 after waiting the designated amount of time (2 sec in the example)

– When the input changes from 1 to 0, it must remain a 0 for a time interval equal to or greater than the time delay before the output will become 0. If the input changes back to 1 before the time delay expires, the output never changes

– When the input changes from 0 to 1, there is no delay in the output changing to 1.

Note: For a TD Off, the designated time (2) is on the right and the units (s) are in the middle.

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Time Delay Off

0 1 2 3 4 5 6 7 8 9 10 time [s]

0 1 2 3 4 5 6 7 8 9 10 time [s]

20

Output

Input

2s 2ss

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Max Pulse Generator (Pulse Generator)• A binary device that limits the time of the

output signal to a specific duration–With an input signal of extended time

duration, the output signal will be converted to an output (pulse) of a specified duration. The duration of the output signal (pulse) is defined in the middle portion of the rectangular symbol, in the symbol shown the output (pulse) duration is max. 2 seconds. If the input reverts to a 0 before the time period is complete, the output will immediately follow the input to the 0 state.

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Max Pulse Generator

0 1 2 3 4 5 6 7 8 9 10 time [s]

0 1 2 3 4 5 6 7 8 9 10 time [s]

2s

Output

Input

2s 1sMAX

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Pulse Generator (One Shot)• A pulse generator

–With input signals of varying time duration, the output signal will be converted to an output (pulse) of a specified duration. If the input signal is a logical 1 for greater than the specified duration, the output will be a logical 1 for the specified period of time (Input = 1 for 3 seconds, Output = 1 for 2 seconds). If the input signal is a logical 1 for less than the specified duration, the output will remain a logical 1 for the specified period of time (Input = 1 for 1 second, Output = 1 for 2 seconds).

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Pulse Generator (One Shot)

0 1 2 3 4 5 6 7 8 9 10 time [s]

0 1 2 3 4 5 6 7 8 9 10 time [s]

2s

Output

Input

2s 2s

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TIME TAGGING DEVICE

Data (Time Tagging Devices)

Binary time tag device, actually called DATA with time binary, records the time and change in a binary state. (FB79)

Analog time tag device, actually called DATA with time analog, records the analog signal and time based on signal change. (FB214)

TTDAP #

TTD AP

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ALARMS FOR BINARY TTD“E” - No Alarm“A” – Alarm (an analog value exceeded its alarm limit)“W” – Warning (an analog value exceeded its warning limit)“T” – Tolerance (an analog value exceeded its tolerance limit)“L” – Local fault has occurred (e.g. “tank level too high” on automatic tank overflow)“M” – Indicates that a Maintenance or service activity is necessary (e.g. “filter clogged; change to spare filter”)“C” – A status has Changed (e.g. changeover to a spare pump)

REV = Reversion of the edge of evaluation of input signal.0 rising edge generates TTD, 1 falling edge generates TTD

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YFR INPUTS AND OUTPUTS

Input signal function blocks are used with a SIM module to enable the AS 620B to read and monitor analog signals from the plant or other processors.

Output signal function blocks are used with a SIM module to enable the AS 620B to send analog signals to components in the plant or other processors.

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Analog Signal Conditioning (FB74)

• The analog signal conditioning function block is used with a SIM module to enable the AS 620B to read and monitor analog signals from the plant.

I

KGAISIG

ATGS4

LV1 LV2

LV4 LV3

ULLL1 ULLL2

ULLL4 ULLL3

CHANNEL LRV

UNIT URV

GS3GS2GS1

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ANALOG SIGNAL CONDITIONING INPUT

• I =Analog Input LV = Limit Value• LRV = Physical Lower Limit URV = Physical Upper Limit• ULLL = Upper (1 or UL) or lower (0 or LL) limit value• UNIT = Defines measuring units (C or Bar, etc.)• GS = When limit reached becomes a 1 output• AI SIG = Analog signal output• KG = Outputs is 1 when analog signal input is OK

I

KGAISIG

ATGS4

LV1 LV2

LV4 LV3

ULLL1 ULLL2

ULLL4 ULLL3

CHANNEL LRV

UNIT URV

GS3GS2GS1

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ANALOG TRANSMITTER INPUT TYPES

• AT - This FB74 is used for analog input signals of 0-20 or 4 - 20 ma.

• RT - This FB77 is used for sensor conditioning of Resistance Thermometers.Input in S.

• TT - This FB76 is used for sensor conditioning of Thermocouples, J & K type. Input in mV.

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I

KGAISIG

ATGS4

LV1 LV2

LV4 LV3

ULLL1 ULLL2

ULLL4 ULLL3

CHANNEL LRV

UNIT URV

GS3GS2GS1

11 13

LL LL 0

20 PSIG

-2

0 1 0 0

13.96 ma

112.45

-2

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ANALOG SIGNAL CONDITIONING

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ANALOG SIGNAL CONDITIONING

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BINARY SIGNAL CONDITIONING INPUT

• I = Binary Input• BI SIG = Binary signal output• KG = Outputs is 1 when binary signal input is OK

I

KGBISIG

BT CHANNEL

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LIMIT MONITOR

• The limit monitor takes an input analog variable (X) and compares it to a setpoint (GW). If the setpoint is reached, a limit signal (SWITCH) is placed on the output (Q).

• A hysteresis, or dead band, can also be assigned to the setpoint to prevent rapid toggling of the output.

• Can be used as a high or low monitor by setting switch value.

Q

XSWITCH

HYS

GW

Analog or Binary?

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LIMIT MONITOR HIGH MODE

• Switch is set to 1• When X input is below

GW setpoint of 225, the Q output is a 0

Q

XSWITCH

HYS

GW

13

225

179

0

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• When the X input exceeds the GW setpoint of 225, the Q output changes to a 1Q

XSWITCH

HYS

GW

13

225

225

1

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• When the X input exceeds the GW setpoint of 225, the Q output changes to a 1

• As the X input decreases below GW setpoint, the Q output remains a 1,

Q

XSWITCH

HYS

GW

13

225

224

1

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• Switch is set to 1• When X input is below GW

setpoint of 225, the Q output is a 0

• When the X input exceeds the GW setpoint of 225, the Q output changes to a 1

• As the X input decreases below GW setpoint, the Q output remains a 1, until the value goes below the setpoint minus the hysteresis which would be 225 - 3 = 222 for our example

Q

XSWITCH

HYS

GW

13

225

222

1

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LIMIT MONITOR LOW MODE

• Switch is set to 0• When X input is above


Q

XSWITCH

HYS

GW

05

3510

3600

0

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• When the X input decreases below the GW setpoint of 3510, the Q output changes to a 1Q

XSWITCH

HYS

GW

05

3510

3510

1

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• When the X input decreases below the GW setpoint of 3510, the Q output changes to a 1

• As the X input increases above GW setpoint, the Q output remains a 1,

Q

XSWITCH

HYS

GW

05

3510

3513

1

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• Switch is set to 0• When X input is above GW

setpoint of 3510, the Q output is a 0

• When the X input decreases below the GW setpoint of 3510, the Q output changes to a 1

• As the X input increases above GW setpoint, the Q output remains a 1, until the value goes above the setpointplus the hysteresis which would be 3510 + 5 = 3515 for our example

Q

XSWITCH

HYS

GW

05

3510

3515

0

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ANALOG SWITCH ASW (FB115)

• The analog switch function block optionally switches one of two analog inputs to the Y output.

• X1 and X2 are analog inputs, SWITCH is a binary input and Y is an analog output.

• Figure is drawn in the “de-energized” position or as if the switch input was a 0.

F

#

Y

SWITCH

X2X1

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ANALOG SWITCH ASW

• With the switch input set to 0, the X1 input is passed to the Y output.

F

#

210 223

210

0

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ANALOG SWITCH ASW

• With the switch input set to 1, the X2 input is passed to the Y output.

F

#

210 223

223

1

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MATHEMATICAL FUNCTIONS

Summation and Subtraction

++

-+

+-

Analog or Binary?

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Multiplication and Division

X1X2

14.5

X

Analog or Binary?

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Maximum & Minimum Functions

X1

X2

MAX

X1

X2

MIN

Analog or Binary?

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Mean Value (Average Function) (FB 189)

X1

EN1

X2

EN2

X3

EN3

Σ/n

AVER

Analog or Binary?

Determines the mean value of up to 16 analog inputs. EN must be a binary one to use that signal.

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Absolute Value (FB67)The function block AV Absolute Value calculates the absolute value of an analog input value. Positive and negative values are represented as positive numbers.

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PRESELECTION FB137

• The preselection function block allows the AS 620 B to store an operators preselections

• Precedence:–Selection 1–Selection 2–Selection 3

OMSELECTENSELM

COMSEL1

COMSEL3

COMSEL2

CBSEL1

CBSEL3

CBSEL2

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PRESELECTION

• EN SELM = Enable Selection Module• COM SEL1 = Automatic command “set binary output “• CB SEL1 = When selection 1 is selected, output is a 1, all

other CB SEL outputs will be a 0.

OMSELECTENSELM

COMSEL1

COMSEL3

COMSEL2

CBSEL1

CBSEL3

CBSEL2

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PRESELECTION OF 1

OMSELECTENSELM

COMSEL1

COMSEL3

COMSEL2

CBSEL1

CBSEL3

CBSEL2

1 1

1

0

0 0

0

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PRESELECTION OF 2

OMSELECTENSELM

COMSEL1

COMSEL3

COMSEL2

CBSEL1

CBSEL3

CBSEL2

1 0

0

1

1 0

0

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PRESELECTION EXAMPLE

Pulse output or continuous

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ANALOG SELECTION 2-OUT-OF-3

Deviation allowed

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DELAY ELEMENT FB84

T

Y

X• Smoothes analog signals

• This function block acts as a delay element to smooth analog input values.

• X – Analog input

• Y – Smoothed analog output

• T – Delay time in seconds

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Fuzzy Logic Controller

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Acknowledgement

Best regards to:Ditmar ReppmanMajid Dini

Contact:0935 2223936e.mail:[email protected]

Any question?

mailto:[email protected]

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