ALSTOM HYDRO TURBINE SPEED GOVERNING SYSTEM

Transcription

1 ALSTOM HYDRO TURBINE SPEED GOVERNING SYSTEM POWER

2 ALSTOM HYDRO CONTROL SOLUTIONS Alstom Hydro, the world s hydropower market leader, acts as a plant integrator, providing both complete power plant solutions and separate products from the overall range, in response to specific customer needs. Hydro plant control solutions cover all plant control requirements including: Integrated control systems Turbine governing systems Generator excitations Protections Condition monitoring Hydro process application software In order to guarantee safe, reliable and optimized power plant operations, Alstom Hydro has developed and qualified specific turbine speed governing systems. With over 100 years experience in the field of turbine speed regulation, Alstom Hydro proposes cost-effective, reliable, innovative, customized governing solutions to its customers. The governing system is an essential part of the overall plant control system. It provides the turbine with the feedback mechanism to control its speed under all circumstances. By regulating the flow of water passing through the turbine, the governor adjusts the power output being sent to the grid. This is done by opening and closing the wicket gates of Francis and Pump turbines, the wicket gates in conjunction with the blades of Kaplan and Bulb turbines, or the injectors and deflectors of Pelton turbines. THE MAIN FUNCTIONS OF THE GOVERNING SYSTEM Control of the turbine start-up and shutdown sequences Synchronisation of the turbine with the grid Control of the active power supplied by the generator to an interconnected network Control of network frequency on an isolated electrical network Protection of the unit against overspeed in case of load rejection Control of advanced sequences 2

3 Reservoir ELECTRICAL NETWORK Plant distributed control system Generator SHAFT SPEED SERVOMOTOR POSITION Speed governor Oil pressure unit Servomotor Actuator Guide vanes / Injectors Runner Pressure tank Governing system architecture THE GOVERNING SYSTEM The governing system is comprised of electronic and oleo-hydraulic parts including: The turbine speed load governor (T.SLG) controller with the hydro process application software The oil pressure unit THE NEYRPIC T.SLG One of Alstom Hydro s latest innovations is the NEYRPIC T.SLG, which has been installed in a large number of power plants worldwide over a very short period of time. The NEYRPIC T.SLG is a state-of-theart controller, capable of performing a large number of additional functions compared to standard systems, in order to optimize plant operations, increase safety, and simplify maintenance. This universal controller is designed for use on all types of hydro turbines, with an unlimited power range, for both new and refurbished power plants. Moreover, it is capable of working under all conditions and is easy to update and maintain. Its proven application software includes a large set of advanced functions covering virtually all process requirements. This software was specifically designed to facilitate parameterisation and diagnosis, making it quick-and-easy to use without necessitating softwareprogramming expertise. Parameters only need to be configured in the system once during the installation phase of the project. In addition, its plug-n-play hardware is compact and modular and extremely easy to operate and maintain. THE OIL PRESSURE UNIT Alstom Hydro s complete solution for the oleo-hydraulic part of the governing system is the oil pressure unit. The unit includes actuators, sump tanks, pressure tanks, a compressed air station, sensors and safety systems and it is critical for overall power plant availability. As the actuator is one of the key hydraulic components, Alstom Hydro developed a complete range that is better adapted to customer needs. Alstom Hydro actuators have a reduced number of individual parts compared to other products available on the market. They are extremely reliable and capable of withstanding harsh turbine operating conditions such as vibration levels, water content, and low oil filtration (up to 150 µm). 3

4 THE NEYRPIC T.SLG DESIGN CONCEPT The NEYRPIC T.SLG has a modular system designed to operate in the most extreme operating conditions. It is characterised by its robustness, high level of adaptability, and simplicity. The system is made up of two dedicated, optimized modules, the unit processing controller (UPC) and the servo positionning controller (SPC), which when combined meet all turbine governing application requirements. It can be interfaced with all types of control systems via a digital bus and/or wired inputs/ outputs (I/O s). figuration is obtained by combining several modules for each type of turbine. The system can therefore control: Up to 24 independent wicket gates for Francis and Pump turbines Both blades and wicket gates for Kaplan and Bulb turbines From 1 to 8 deflectors and 1 to 8 injectors for Pelton turbines RANGE OF APPLICATION The modularity of the NEYRPIC T.SLG makes it suitable for all turbine models. The best cost/function con- 4

5 WHY CHOOSE AN ALSTOM HYDRO GOVERNING SYSTEM? Extremely reliable and robust, designed by hydro market leader Design fully adapted to hydro application needs Universal system for all turbine models, for both new and refurbished plants Easy to install and operate Improved serviceability Long term support Alstom Hydro completely assembles, tests and pre-configures the electronic and oleo-hydraulic parts of the governing system at its ISO 9001:2000 manufacturing sites worldwide. THE UNIT PROCESSING CONTROLLER MODULE (UPC) The UPC module performs the most complex turbine control functions including: Highly accurate rotation speed regulation for synchronisation with the grid, using a specific integrated electronic circuit capable of taking 3 measurements Power/load adjustment Frequency regulation Integration of 2D and 3D laws and numerous parameters to optimize turbine operating Specific advanced functions for each type of turbine (such as jet dispatcher for Pelton, on-cam operation for Kaplan, individual wicket gate control for Pump turbine etc.) multi-level redundancy (SPC, UPC, sensors). THE SERVO POSITIONING CONTROLLER MODULE (SPC) The SPC module carries out servomotor position control via a single or double loop position control. Equipped with a universal amplifier, it can control all types of actuators including third party equipment. The NEYRPIC T.SLG can handle up to 24 independent SPC modules, therefore permitting individual gate control for Pump turbines. Moreover, the SPC has both redundancy and hot swap capabilities. 5

6 THE TURBINE AUXILIARY DIGITAL TACHOMETER (T.ADT) In addition to the standard UPC and SPC modules, the NEYRPIC T.SLG can also have other modules easily added-on such as the T.ADT. The T.ADT is the ideal product for customers who require a standalone independent tachometer for measuring turbine output with speed thresholds. Designed on the same platform as the T.SLG, the T.ADT can easily work in combination with the NEYRPIC T.SLG governing system. It is a good choice of solution for both new plants and for upgrading outdated mechanical systems in old plants. The T.ADT functions cover: Speed measurement Speed signal redundancy with up to 3 sensors Speed threshold programming and control The T.ADT also offers advanced functions not included in the UPC module such as: Rotation direction detection Creep and stop detection 12 programmable speed thresholds 6

7 THE HUMAN MACHINE INTERFACE (HMI) The HMI is the interface used by the operator to manage and adjust the NEYRPIC T.SLG parameters. Using a flat-panel touch screen, the operator can intuitively navigate through the menus using the graphical user interface. The HMI can be customized in the user s language. Based on Alstom Hydro s experience and know-how, the HMI has all the features a plant operator requires including: Analogue and digital graphic indicators (speed, gate, power, etc.) Quick access to device parameters The T.SOFT DIAGNOSTIC TOOL Alstom Hydro s T.SOFT maintenance software allows plant operators to monitor and troubleshoot problems autonomously. This user-friendly tool features clear mimics, easy access to parameters, and produces different types of alarm and event messages with clear instructions for resolving the problem. The main functions of T.SOFT are: Uploading of application software Downloading and storing of parameters Reading and forcing of I/Os Diagnosing a large number of test points using an integrated real-time oscilloscope Tuning of parameters Data recording (Historian) Local and manual mode Fault recorder The software runs on any standard Windows laptop. T.SOFT communicates with both the T.SLG and the T.ADT via an Ethernet connection. 7

8 THE OIL PRESSURE UNIT The oil pressure unit is specifically designed to manage and regulate large volumes and flows of oil. For each customised unit, Alstom Hydro prioritises robustness and simplicity in order to maximise reliability and minimise maintenance. The standard oil pressure unit operates under a pressure of 64 bars, however Alstom Hydro frequently provides higher pressure 160 bar units. The high pressure units are advantageous because they require smaller servomotors and associated parts. In addition, they use bladder or piston accumulators, thus eliminating the need for a compressed air station. ALSTOM HYDRO NEYRPIC ACTUATOR RANGE The actuator is one of the key hydraulic components required for turbine speed control. It consists of an electro-mechanical device that transforms the electrical signal coming from the NEYRPIC T.SLG into a mechanical command, sending oil to the servomotor to control turbine rotation speed. In addition to using standard market products, Alstom Hydro has been developing in-house customised actuators for over 100 years, gaining a high level of expertise in this specific field. The range of actuator products it has designed is extremely reliable and perfectly suited to the functions they have to fulfil. They have a proven lifetime of over 40 years, requiring little or no maintenance during that time. Alstom Hydro can provide a complete range of actuators in order to control all types of hydraulic turbines regardless of the oil flow required to move the servomotors (from a few litres to several cubic meters per minute). The full range includes single-stage, double-stage and flanged actuators. SINGLE-STAGE (ED Series) Single-stage actuators such as the ED12, ED25 and ED35 are suitable for oil flows less than 500 l/min. These electro-hydraulic transducers convert the electric signal from the electronic speed governor into a hydraulic flow/ pressure signal on the servomotor. DOUBLE-STAGE (D SERIES) Double-stage actuators combine a TR10 electro-hydraulic transducer with a main distributing valve such as the D50, D80, D100, D150 and D250 models. The TR10 converts the electricsignal into a hydraulic flow (up to 20,000 l/min) to open the main distributing valve. FLANGED ACTUATORS (DF Series) Alstom Hydro has developed an integrated all-in-one actuator range that includes all servomotor functions and eliminates the need to purchase and connect several individual standard products. These actuator models, which include the D50F, D80F and the D100F, are very compact and don t require external piping, thus ensuring greater reliability and reducing maintenance requirements. In addition to its principal function of connecting the electro-hydraulic transducer to the main distributing 8

9 ALSTOM HYDRO ACTUATORS ARE BETTER BECAUSE THEY ARE: Reliable & robust Perfectly adapted to hydraulic turbines Fully compatible with the NEYRPIC T.SLG Require little or no maintenance Covered for service for the lifetime of the plant ED Series D Series DF series valve, the flanged actuator model can also include a manoeuvring time adjustment orifice, an emergency shutdown solenoid valve, an overspeed relay, a multi-slope closure law valve and redundant sensors. Designed, manufactured and tested at the Alstom Hydro Global Technology Centre, these plug-and-play systems help to increase turbine performance and reliability. They also eliminate the need for specific performance tests that are normally carried out on site for each project. Alstom Hydro Oleo-Hydraulic Ancillary Devices The Alstom Hydro product range also includes a number of oleo-hydraulic ancillary devices such as: An overspeed detector An accumulator insulation valve These can be used as plug-n-play devices and have the same integration advantages as flanged actuators. Alstom Hydro s overspeed safety detector is a completely mechanical device installed on the shaft line. It uses centrifugal force to detect excessive runner rotation speed and sends out a hydraulic signal that can be used to close the main distributing valve and stop the turbine, without using the electronic controls. The accumulator insulation valve separates the accumulator from the governing circuit in order to prevent air from entering into it. By maintaining the governing system under pressure, it enables servomotor control in the power plant (even when the pumps are switched off), ensuring faster start-up under normal conditions and enabling black start. 9

10 Alstom Hydro s PLANTLIFE SERVICE PROGRAMME Alstom Hydro can provide speed governing system owners with a comprehensive service programme covering installation, training, maintenance, spare parts and rehabilitation in more than 70 countries worldwide. Known as the Hydro PlantLife programme, it ensures that customers obtain a rapid, comprehensive response from experienced local teams and dedicated customer support centres. Alstom Hydro is the leading partner for all customers looking to optimise their investment and to secure their control equipment during the lifetime of their plant INSTALLATION, TRAINING, MAINTENANCE, SPARE PARTS AND REHABILITATION Basic and advanced product training courses are available at Alstom Hydro regional training centres, to optimise both the use of equipment and maintenance operations. A training simulator is available and can be configured with each specific customer application. In addition, Alstom Hydro can provide plant operators with on-site training during the commissioning phase of projects, so that they are ready as soon as the plant starts operating. Alstom Hydro can also repair or replace spare parts using different types of spare part contracts, to meet a wide range of customer requirements. Moreover, the NEYRPIC T.SLG design facilitates quicker maintenance operations. It can be initially installed in a simplex configuration and easily upgraded to full redundancy at a later stage. Thanks to a modular design dedicated to Hydro applications, the NEYRPIC T.SLG can address the specifications of any hydro power plant rehabilitation project. A large number of worldwide references are available, including emergency response within a few months time frame. 10

11 ALSTOM HYDRO GLOBAL PROJECT HIGHLIGHTS CANADA La Grande - new: 33 turbine/generator units, 8654 MW. US Shasta - refurbishment: 5 x 142 MW turbine/generator units. MEXICO Chicoasen - new turnkey supply : 3 x 310 MW turbine/ generator units, control system. BRAZIL Itaipu - new: 10 x 700 MW turbine/generator units, control systems. Tucurui - new: 11 x 370 MW turbine/generator units, control system. VENEZUELA Guri 1 - refurbishment Francis: 4 x 400 MW turbine/ generator units. PORTUGAL Alqueva - new pumped storage: 2 x 130 MW turbine/ generator units, control system. NORWAY New Tyin - new: 2 x 220 MVA generators, BOP, control system. SWITZERLAND Chancy Pougny - refurbishment: 2 x 12 MW turbine/ generator units. TURKEY Uzundere - new: 2 x 30 MW turbine/generator units. FRANCE Grand Maison - new pumped storage: 12 x 157 MW turbine/generator units. MOROCCO Afourer - new pumped storage and irrigation: 2 x x 60 MW turbine/generator units, BOP, control system. SUDAN Merowe - new turnkey supply: 10 x 125 MW turbine/ generator units, BOP, control system. ZAMBIA Victoria Falls - refurbishment of 2 small power stations: 108 MW turbine/generator units. CHINA 3 Gorges - new: 14 x 700 MW turbine/generator units, 14 governors, control system. Huizhou, Bailianhe and Baoquan - new, 3 pumped storage plants: 16 x 306 MW turbine/generator units, BOP, control system. SOUTH KOREA Yang Yang - new pumped storage: 4 x 250 MW turbine/generator units with adjustable double-stage. INDIA Subansiri - new turnkey supply: 8 x 250 MW turbine/ generator units, control system. VIETNAM Se San 4 - new: 3 x 120 MW turbine/generator units. Dai Ninh - new: 2 x 150 MW turbines, control system. Dai Ninh - refurbishment: 4 x 40 MW control system. MALAYSIA Bakun - new: 4 x 315 MW turbine/generator units, BOP. AUSTRALIA Trevallyn - refurbishment: 4 x 30 MW turbine/generator units. NEW ZEALAND Manapouri - upgrade: 7 x 135 MVA generators. 11

12 PWS/BPROB/HTSGS09/eng/HYD/03.09/FR/6823 ALSTOM All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. - Photo credits: Alstom Design & Layout: PLANT INTEGRATOR and PlantLife are trademarks of Alstom. NEYRPIC is a registered trademark of Alstom. ALSTOM Hydro 4, avenue André Malraux Levallois Perret Cedex - FRANCE