Reliability and Safety for the Energy Supply Industry
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1 Keli 2010 Helmut Mauell GmbH Reliability and Safety for the Energy Supply Industry Power Station ti Control System ME 4012: Structures Functions Engineering Application Examples 1
2 Power Station Control Vertical Integration and Project Organisation Development Consulting Engineering g Manufacture Installation Commissioning Training Product Maintenance Worldwide Service
3 Gas Turbine Control System ME 4012: Power Plant Altbach Combined Cycle Unit 4 Steam power Injection Boiler drum Flue gas 200MW Water pipes pp Steam turbine Oil Gas Sek. - Prim. superheater Siemens GT V93.0 Oil Gas Fire Area Feed water flow M Burner Compressor Turbine Cooler Demineralize 50MW Oil Gas M Combustion chamber 3
4 E.ON Power Plant Heyden Turbine Control System 920 MW Unit data: Power: 920 MW Live steam: T = 544 C P = 210 bar Intermed. Super Steam: T = 544 C P = 46 bar Construction 1987 Operation hours: 110,000 h Start-ups:
5 City Heating and Power Plant Station Munich South Fernwärmenetz Munich district heating München network 5
6 Municipal Supplier Munich GuD-Plant DHP Munich South GuD 1 (old plant): - 2 Gas turbines with120 MW el - Steam turbine with 83 MW el - 2 heat recovery boilers, 260 MW t/h - Waste water treatment plant - 3 auxiliary steam generators, 3 x 36 MWt/h GuD 2 (new plant): - 2 Gas turbines (F9E) with 150 MW el - Steam turbine with 150 MW el - 2 Heat recovery boilers District heating network Munich: 1,700MW t/h 6
7 Vattenfall Brown Coal Power Plant Boxberg Unit R, 670 MW el 7
8 Vattenfall Black Coal Power Plant Moorburg: 2 x 820 MW el, 2 x 450 MW th 8
9 Electrabel / Tractebel Nuclear Power Plant Tihange Turbine Control 2 x 1100 MW 9
10 Power Station Control Engineering and Diagnosis System ME-DRP and ME-VIEW Client Workstation 1 Workstation 2 Workstation n up to 32 screens ME-DRP Server / Client ME-VIEW Client cold standby ME-VIEW monster client 32 ME-VIEW Client ME-VIEW Client VIEW-LAN Intranet Firewall Location Remote maintenance Mauell / Velbert DRP switch (Rail) VIEW switch 1 VIEW switch 2 Router PD-Server s 1 PD server 2 RAID 5 PD switch 1 RAID 5 PD switch 2 DRP-/ PD- LAN SUB-NET Level B GPS / DCF77 SUB-NET coupler AE4012 automation unit SUB-NET SUB-NET SUB-NET coupler coupler coupler Clock AE4012 automation unit SUB-NET Level A SUB-NET Level A Multi function processor Multi function processor Multi function processor Multi function processor Multi function processor Multi function processor Multi function processor Multi function processor Multi function processor Multi function processor Binary input / output Analog input / output Binary input / output Analog input / output Binary input / output Analog input / output ME-VIEW ME-DRP Binary input / output Analog input / output Binary input / output Analog input / output Binary input / output Analog input / output RV 10
11 ME-VIEW System Architecture Workstation1 Workstation n max. 32 screens ME-VIEW Client cold standby ME-VIEW Monsterclient ME-VIEW Client VIEW-LAN VIEW-switch 1 VIEW-switch 2 Engineering- u. Diagnosis-System ME-DRP and ME-VIEW-Client Router Firewall RAID 5 RAID 5 Intranet PD-switch 1 DRPswitch PD-switch 2 ME-DRP Server / Client ME-DRP Client ME4012 distributed coupling ME4012 distributed coupling DRP-LAN 11
12 RWE Brown Coal Power Plant Frimmersdorf House Load Dispatcher for 16 Units 12
13 RWE Brown Coal Power Plant Frimmersdorf Location House Load for 16 Units 14x 150 MW, 2x 300 MW Electric Control Room New Electric Control Room 13
14 Modern Control Algorithms Applied in Power Station Control NOx,SO,CO 2 2 E-Filter DeNO x FGD In Situ 1 2 heating value correction 3 boiler free load burnout air 8 In Situ SG max. 535 C 164 bar 165 bar soot blower 0 C 5 5 FD SH 34 bar 4 max. 525 C 7 Stressmonitor HP IP LP f P E MW lignite or coal primary air secondary air coal level Freeness M M mill speed 6x 6 Combustion chamber T-monitoring and T-allocation densate Con 66 mbar 1. Unit model (smooth load control) 2. Condensate stop control 3. Multi-variable Fuzzy control 4. Turbine Speed- / Load Control 5. Calculation-guided control 6. Combustiom analyse control 7. Turbine Stress Monitor 8. Boiler free load calculation 14
15 CAE for Engineering ME-DRP 5: Functional Scope Plant topology System structure Plant scheme Flow Function Hardware diagrams plans assignment Device list Interconnection diagrams Installation diagram 15
16 ME-DRP 5 Project Management and Structures Provided by the customer Function decriptions Manufacturing guidelines Standards Plant schemes (R+I) Sensor/ actuator lists Basic engineering Project execution Master data Project definitions HW design SW design Device location Field planning Function plans Operation Control Signal processing Process objects Reports Archive Logic Recording Process objects Plant Section A Section A1 Section A1.1 Process object Function Project design standards Project manual Mauell regulations Site-specific regulations Project database Document Section B Site-specific documentation and configuration Cubicles Kabelliste Function Control plans Distribution box Distr.box assignment Circuit diagrams Process objects Closed loop control Standard diagrams Manufacturing orders Installation and IBS documents Documents and lists Test reports Hardware + Functiondocumentation Configuration files Operation files Source Code 16
17 Kohleförderung ME 4012 Engineering System ME-DRP 5 Documentation, Configuration, Diagnosis Administration 1. DRP-Workstation 2. DRP-Workstation Workstation 1 Workstation 2 ME-DRP ME-DRP ME-DRP ME-VIEW ME-VIEW ME-VIEW ME-VIEW ISDN DVD-writer Docum.- printer Router ME-VIEW client VIEW-LAN ME-VIEW client Projectdatabankserver DRP-LAN PD-server 1 PD-server 2 RAID 5 PD-LAN RAID 5 SUB-NET Elektronicroom n. DRP-Workstation AE4012 AE4012 AE4012 AE4012 AE4012 AE
18 Control System for the Implementation of Dedicated Climate Change Targets For example: Vattenfall s target of carbon dioxide reduction CO 2 -Reduc ction by 0 % EU-Target 20 % 50 % 90 % Vattenfall-Target I: emission reduction by 50% until 2030 emission reduction by 20% until 2020 Vattenfall-Target II CO 2 neutrality until Basis EU & Kyoto 18
19 Vattenfall Black Coal Power Plant Moorburg: 2 x 820 MW el, 2 x 450MW th 19
20 Vattenfall Black Coal Power Plant Moorburg: 2 x 820 MW el, 600 MW th Net efficiency without district heating 46,5 % Fuel utilisation with district heating up to 57,2 % Live steam temperature 600 C Intermediate super steam temperature 610 C Live steam pressure 276 bar Effective power (electrical) 1,640 MW District heating extraction up to 600 MW 20
21 Vattenfall Black Coal Power Plant Moorburg: 2 x 820 MW el, 600 MW th 21
22 Vattenfall Black Coal Power Plant Moorburg: 2 x 820 MW el 600 MW th 22
23 Vattenfall Black Coal Power Plant Moorburg: 2 x 820 MW el 600 MW th 23
24 Vattenfall Brown Coal Power Plant New Construction Boxberg Block R, 670 MW el New Construction Unit R 24
25 Vattenfall Brown Coal Power Plant Boxberg, Unit R Base load operation Availability > 91 % Unit guide control 50 % to 103 % High level of automation Fulfillment transmission code Net efficiency > 43,7 % (live steam: T = 600 C; p = 285 bar) Coal demand: 4,5 Mio. t/a Specific CO 2 -Emission: 924 g/kwh 25
26 Vattenfall Power Plant Boxberg Schematic Diagram of Unit R, 670 MW el m m Cooling tower and flue-derivation Flue gas desulfurization plant Induced draft fan Electrical filters Steam generator Turbine building 26
27 Vattenfall Power Plant Boxberg, Unit R, 670 MW el 27
28 Vattenfall Power Plant Boxberg, Unit R, 670 MW el 28
29 Vattenfall Power Plant Boxberg, Unit R, 670 MW el 29
30 Vattenfall Power Plant Boxberg, Unit R, 670 MW el 30
31 Electrabel / Tractebel Nuclear Power Plant Tihange 3 Turbine Control 2 x 1100 MW, 4 x SPAT 31
32 Electrabel / Tractebel Nuclear Power Plant Tihange 3 Turbine Control 2 x 1100 MW, 4 x SPAT 32
33 Electrabel / Tractebel Nuclear Power Plant Tihange 3 Turbine Control 2 x 1100 MW, 4 x SPAT 33
34 Electrabel / Tractebel Nuclear Power Plant Tihange 3 New Control Panel for the Turbine 34
35 KELI 2010 Helmut Mauell GmbH Reliability and Safety for the Energy Supply Industry Thank you for your attention. For more information click here DA E10 KELI 2010: Process Control System ME May
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