TRACK 5: ELECTRICAL & AUTOMATION FOR POWER

GENERATION
SECTION 2 : TURBO MACHINERY CONTROL
Innovative Automation Technology for Gas & Steam
Turbine Control to Optimize Plant Performance and
Grant Great Flexibility

Vienna, June 04, 2013

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

POWER-GEN EUROPE 2013 -VIENNA

Innovative Automation Technology for Gas & Steam
Turbine Control to Optimize Plant Performance and
Grant Great Flexibility
Mr. Mario Barisione

ANSALDO GT Automation Department

Mr. Giuseppe Ferrari ABB Power Systems I&C Automation

Mr. Carlo Bima

ANSALDO ST Automation Department

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

ANSALDO-ABB OEM AGREEMENT

Ansaldo Energia provides plant engineering and construction for turnkey
power plants, including process, mechanical, civil, installation and start-up
engineering.
The main components manufactured by Ansaldo are gas turbine, steam
turbines and electrical generators, where the advanced technology is
designed to satisfy the most demanding customer requirements in terms of
efficiency, reliability and environmental impact.
Ansaldo Energia is leading provider of services for all types of electric
power plant, offering assistance at all levels of complexity for its own and
third party machinery. It handles all after sales issues with a broad range of
global services, ranging from repairs and spare parts, to on-site work
including overhauls and upgrades, right through to full service or O&M Long
Term Agreements.

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

ANSALDO-ABB OEM AGREEMENT

ABB is a global leader in power and automation technologies.

ABB is a leading provider of integrated power and automation
solutions for conventional and renewable based power generation
plants.
The companys extensive offering includes turnkey electrical,
automation, instrumentation and control systems supported by a
comprehensive service portfolio to optimize performance, reliability, and
efficiency while minimizing environmental impact.
For more than 40 years, ABB has provided control systems for turbine
applications, equipping all types of rotating machinery worldwide,
representing over 30 different turbine OEMs.

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

ANSALDO-ABB OEM AGREEMENT

Cooperation between Ansaldo Energia, as turbine manufacturer, and ABB,

as control system provider, has started more than 30 years ago, and, during
such a long history, has produced standard solutions for hundreds gas and
steam turbine packages as well as plant DCS applications based on INFI 90
and Symphony Harmony ABB products.
To continue the cooperation ANSALDO and ABB studied an advanced gas
and steam turbine control systems based on the new ABB Symphony
Plus (S+) platform, evolution of previous Symphony Harmony which allows
the advantage of the up to date technology together with the possibility to
utilized the past experiences made with previous ABB technology.

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

ANSALDO-ABB OEM AGREEMENT

On 2010 ANSALDO and ABB signed an OEM agreement in order to redesign the gas and steam turbine control system based on S+ .
The idea was to develop, starting from all past experiences, a dedicated and
specialized new GT and ST turbine control and protection system that
collects most of the needs expressed by the customer for the automation of
the rotating machines and engineered and tailored for the specific
ANSALDO needs.
This approach includes also the ANSALDO branding of these new GT and
ST control systems extended also to hardware components like processors
and electronics cards.

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS ADVANTAGES

The main advantages and improvements that have brought ANSALDO to
adopt S+ technology have been the followings:
Up-to-date technology supported by ABB continous investement on R&S
for upgradings and improvements
Maintenance easiness with all capabilities offered by smart sensors
Fully integration with the power plant distributed control system (DCS)
Reliability of the safety functions in compliance with IEC 61508 and IEC
61511 standards.
New faster Data Highway based on 100 Mbyte ethernet protocol
Redundancy of the cards which drive the fuel control valves

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS ADVANTAGES

More powerful processors and operator interfaces with the new
generation of high-performance, high-capacity process controller S+
HPC800 (based Freescale Coldfire processors)
Possibility to use the SW developed and tested with the previous
technology Symphony Harmony in accordance with ABB policy of
Evolution without obsolescence
Possibility to visualize on line by the operator station the logics
associated to each drivers
Possibility to centralize the I/O cards with the processors or
decentralized near to the equipment
Capability to integrate both traditional hardwired instrumentation,
profibus field devices with GSD file description and Hart devices
A comprehensive suite of hardware and software modules to fulfill
whatever application requirement in power industry
8

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

Profibus DP V2

Profibus DP V2

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

10

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS
HPC800 PROCESSORS + CP800 COMMUNICATION MODULES

11

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

GAS AND STEAM TURBINE CONTROL SYSTEMS

ANSALDO GT and ST control system with this new technology were focused
on the followings priorities:
Rationalization of the software making it more modular and user friendly
Use of preformed cables to connect signals between different cabinets
Realization of critical protections according to the SIL level requested by
risk analysis
Automatic loading/downloading by excel file of the setting parameters
Improvement of the cyber security and system logging
Development of reference SW for every size of turbines
Redefinition and rationalization of supervision signals (alarms and states)
Modular design of SW to simplify the switch between different turbine
models or configurations
12

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

AE94.3A4 DUAL FUEL S+ GAS TURBINE CONTROL SYSTEM (GTCS) OVERVIEW

S+ Operation
clients

S+ Engineering
tools

A4 color laser
printers

Dot matrix
alarm printers

Service PC

Main control
room

Internet
VPN Client
User: xxxx
Pwd: yyyy

MCR Ethernet box

RSTP

Redundant HMI network (LACP)

AEN to Site VPN
S+ Redundant Plant Network (PRP TCP/IP 100 MB redundant ethernet)
SNTP Time synch. network
S+ Operation
Servers

Fiber optic
link

(Option)

High Integrity
Engineering & OWP

VPN Firewall
Redundant HMI
network (LACP)

SRV1

SRV2

TimeSynch.
SNTP Time Server

SRV3
SIL RNRP redundant
Installed in
network

RSTP

TSI cabinet
(*) 220 = Vdc (SOV supply)

230 ~ Vac (A)

230 ~ Vac (B)

CJR01
Power Distribution

Router Internet
(DSL)

(Option)

CJQ01-CJQ02-CJQ03
TSI Cabinet

Local control room

Profibus DP cables S800 I/O

Preformed cables
CJP01
S+ HPC
Controllers

CJP02
GT ESD SIL3
(5)

CJP03
S800 I/O
(1) (2)

CJP04
S800 I/O
(2)

13

CJP05
S800 I/O
(2)

CJP06
S800 I/O
(3)

CJP07
S800 I/O
(3)

CJP08
S800 I/O
(4)

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

AE94.3A4 DUAL FUEL S+ GTCS HPC CONTROLERS

PNI800
HMI Operations

PNI800
HMI Operations

FUEL CONTROLLER
(1)

GT AUXILIARIES and
SEQUENCER
(2)

CNI800

CNI800

ANCILLARIES. (Non
std aux. , electr. part
etc.) (3)

PNI800
HMI Enginering

GT non-SIL
protections
(4)

CNI800

S+ Redundant Plant Network 100MB Ethernet TCP/IP (PRP)

HPC800

CW800
HPC800

Redundant
CPU

CW800
HPC800

HN800

CW800

Redundant
CPU

HN800

HN800

HPC800

HN800

Redundant
CPU

Redundant
CPU

SNTP Time synch. network

PDP800

PDP800

FL COM
SERVER

to VP800 control
valves drivers
(CJP01 rear)
to/from S800 I/O
Cabinet CJP03
(Clusters A,B,C)

to/from S800 I/O

Cabinet CJP03
(Cluster D)

1 x PDP800
Profibus DP V2
master
(redundant)

CJP01 (front)
CPU cabinet

Modbus

to/from TP800
System 1
GT ESD SIL3
cabinet CJP02

PDP800
1 x PDP800
Profibus DP V2
master
(redundant)

1 x PDP800
Profibus DP V2
master
(redundant)

Profibus DP

Profibus DP

2 x PDP800
Profibus DP V2
master
(redundant)

Profibus DP

PDP800

Profibus DP

PDP800

Modbus interface
To gas chromatograph
(out of ABB scope of supply)

to/from S800 I/O

Cabinet CJP06

14

to/from S800 I/O

Cabinet CJP08

TSI servers
cabinet

AE94.3A4 dual fuel Symphony Plus GTCS redundant VP800 E/H drivers
#1

Datalogger Delphin
ProfiMessage

to fuel gas
hydraulic
valves
#2

MBP22AA151
FG PREMIX CV

#3

MBP23AA151
FG PILOT CV

#4

MBN14AA151
FO DIFFUSION CV

#5

MBN23AA151
FO PREMIX CV

#6

MBN53AA151
FO DIFF. RETURN CV

#7

MBN82AA151
PURGE WATER CV

#8

MBA11AS001
IGV

8 redundant E/H driver for fuel control valves (16 x VP800)

Delphin Extension Bus

15

to fuel oil
hydraulic
valves

to purge water
hydraulic valve
Terminal boards

CJP01 (rear)
CPU cabinet

Profibus DP

to/from Fuel Controller

Profibus DP Master 1
(CJP01 front))

MBP24AA151
FG PILOT 2 CV

to IGV
hydraulic
actuator

Vibration
monitoring

Datalogger
Delphin
AMDT module

AE94.3A4 dual fuel Symphony Plus GTCS SIL3 ESD

Redundant RNRP SIL protections control network
CI SM BC
854 811 810 PM865 HI

GT ESD - SIL3
protections

AC800M

Redundant 24 Vdc
for trip solenoid
supply (SS823
power voters)

HIGH
INTEGRITY

TSI servers
cabinet

PM865 HI

AC800M

HIGH
INTEGRITY

3 x TP800 System 1 (Fuel Controller)

TP800

TP800

Optical
ModuleBus

TP800

ROM810V2
2oo3
hardware
voting

to/from Fuel Controller

Profibus DP Master 1
(CJP01 front))

DI

DI

Cluster 1

DI

AI

DO DO

DO

SIL3
relay

HW interface with S+
GTCS controllers and TSI
by means of preformed
cables (to CJP03, CJP06,
CJP08, CJQ02 cabinets

S800 HI
Ch. A

TB840A
TU847

3 x TP800 System 2 (GT ESD)

TP800

TP800

ROM810V2
2oo3
hardware
voting

Cluster 2
DI

AI

DO DO

DO

SIL3
relay

S800 HI
TB840A
TU847
DI

Profibus DP

DI

DI

Cluster 3
DI

AI

DO DO DO

SIL3
relay

S800 HI

Ch. B

AE94.3A4
dual fuel
I/O trip
signals

Ch. C

TB840A
TU847

3 x I/O Cluster each with:

3 x DI880 =16 ch. 24Vdc SIL3
1 x AI880A =8 ch. 4-20mA, SIL3
3 x DO880 =16 ch., 0,5A SIL3
62 x SIL3 relays

6 x turbine speed
measures from
active pickups

Terminal boards

TP800

DI

CJP02 GT ESD (SIL3) Cabinet

16

Trip solenoid
valve power
supply circuit

To hydraulic oil
trip solenoids for
fuel valves
(cartridge)

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

GAS TURBINE CONTROL SYSTEM

The GTCMPS includes the following six sections totally integrated together:
1. GT auxiliaries control and complete automatic start-up and shut-down
procedures.
2. Fuel control and speed/load control functions for the fast closed loop
functions of the gas turbine (governor).
3. No SIL protection functions dedicated to not critical GT protections.
4. SIL protection functions according in accordance with the IEC 61508 and
IEC 61511 standards.
5. Ancillary systems control: in case that additional BOP systems are
requested to added in the GTCMPS scope of supply.
6. TSI cabinet including Vibrometer rack for bearing vibration measures,
flames monitors and Data Logger Delphin with its pc interface.
17

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

GAS TURBINE CONTROL SYSTEM

The main functions implemented inside the GT governor are:

Speed measures management

Speed/load control
Load/drop control and max load limitation
Exhaust gas control
Run up control
Compressor ratio () limiter
Turbine cooling control
Low value gate selection
Fuel control valves position control
Closed loop for the IGV control
Synchronization
Purging water control
Automatic minimum load pick-up
Generation of the load reference and gradient reference
Interface with the power plant coordinated control
Load drop anticipator
Over-speed tests logic management
18

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SIMPLIFIED SCHEME OF GT FUEL GAS CONTROL

RUN UP
CONTROL

PROPORTIONER

(2)

(2)
SPEED/LOAD
CONTROL

(1)

Valve position SP
calculation (mass
flow computer)

(2)

(3)

LOAD LIMITER

ETA LIMITER

<

(3)

VALVE
POSITON
CONTROL

(4)

PREMIX CONTROL
VALVE

CONTROL OF PILOT
GAS VALVE
(Open loop control based
on GT operational status)

VALVE
POSITION
CONTROL

(4)

EXHAUST GAS
TEMPERATURE
CONTROL

TURBINE COOLING
TEMP. CONTROL

Valve position SP
calculation (mass
flow computer)

(2)

Valve position
SP calculation

(3)

DIFFUSION
CONTROL VALVE
VALVE
POSITION
CONTROL

(4)

(1) Thermal load request [KJ/s]

(2) Flow gas request [Kg/s]
(3) Valve position request [%]
(4) Position valve feedback position [%]

19

PILOT GAS
CONTROL VALVE

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

GAS TURBINE CONTROL SYSTEM

20

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

GAS TURBINE CONTROL SYSTEM

21

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

STEAM TURBINE CONTROL SYSTEM

The STCS meets all the characteristic automation requirements for a
steam turbine automation system with just three sections of an integrated
system:
General automation tasks ranging from the control of the auxiliary
systems through to complete automatic start-up and shut-down
procedures
Protection functions in accordance to Safety Integrity Level 3 (SIL 3),
as required by IEC 61508 and IEC 61511 standards
Governor functions for the fast closed loop functions of the steam
turbine

22

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

STEAM TURBINE CONTROL SYSTEM

The main functions implemented inside the ST governor are:

speed control & speed measure management

continuous generation of the speed and acceleration reference
speed control loop
synchronization
valves position control
closed loop controls of steam turbine control valves position
closed loop control of steam extraction control valves position
full arc / partial arc automatic transfer management
automatic synchronizer interface management
load control and automatic minimum load pick-up
Generation of the load and gradient reference
interface with the power plant coordinated control
load drop anticipator based on power unbalance or accelerometric
protection
valve tests logic management

23

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

STEAM TURBINE CONTROL SYSTEM

24

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS CONTROL SYSTEM INNOVATIONS

GTCMPS and STCS include innovative aspects, such us security, safety,
all-in-one, modular packaging, compactness, one-point-of interface, low
energy consumption.
Only one system provide all automation functions, with all components
integrated and fully tested at factory, before the delivery to site.
Fully integrated solution, including also plant distributed control system
(DCS), with a common platform for control functions, including: engineering
design standards, engineering tools, and operator graphics.
Reduced time and cost for system set-up and installation at site because
new Symphony Plus has no dipswitch or jumper for hardware set-up.
Symphony Plus controllers utilize DIN-rail form factor, standard 24 Vdc
power inputs, and a standard Ethernet network to make installation simple
and flexible.
25

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS CONTROL SYSTEM INNOVATIONS

The overall dimensions of new GTCMPS and STCS are lower than
previous Ansaldo-ABB turbine solutions (25% less)
Lower power consumption
Cabinets fanless and then completely no noise production
The Symphony Plus turbine control solution provides complete diagnostic
for every type of fault
Specific system routines monitor the good operation
External field power supply monitored including solenoids
Fully hardware redundancy for each component including I/O modules for
speed measurement and valve positioning
26

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS CONTROL SYSTEM INNOVATIONS

TP800 is the turbine measurement and protection module that provides a
complete set of safety certified functions for comprehensive turbine
protection, such as overspeed trip, load drop anticipation and power/load
unbalance.
Speed 2oo3 redundancy is the state of art for every turbine manufacturer,
but 100% hardware redundancy of valve positioning is peculiar of Symphony
Plus solution.
VP800 is the valve positioner module that provides the capability to
implement a fully redundant configuration sharing both output commands
and feedbacks, allowing to preserve module redundancy even in case of a
LVDT or a coil failure.
Switching between the two VP800s is bumpless and instantaneous, not
affecting the valve control.

27

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS CONTROL SYSTEM INNOVATIONS

28

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SYMPHONY PLUS CONTROL SYSTEM INNOVATIONS

TP800 SPEED ACQUISTION CARDS AND VP800 VALVE POSITIONER

29

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

TURBINE PROTECTION AND SAFETY

30

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

TURBINE PROTECTION AND SAFETY

THE DEFINITIONS OF THE PROTECTIONS TO BE ELABORATED AT SIL
LEVEL HAVE BEEN DONE STARTING FROM A RISK ANALYSIS BASED
ON THE FOLLOWING CRITERIA:
IN COMPLIANCE WITH IEC 61511 AND IEC 61508, THE DETERMINATION OF THE SECURITY
INSTRUMENTED FUNCTIONS (SIF) AND THEIR SAFETY (SIL) ARE PERFORMED ON THE
BASIS OF AN HAZARD AND RISK ANALYSIS RELATED TO:
q SAFETY OF POWER PLANT STAFF
q SIGNIFICANT EFFECTS OF ENVIRONMENTAL POLLUTION
THE ABOVE AS WELL AS THE COMPLETE GAS TURBINE CONTROL SYSTEM WERE DONE
IN CONJUNCTION WITH THE COMPLIANCE TO ALL EUROPEAN DIRECTIVES AND TO THE
ANSALDO GENERAL POLICY RELATED TO THE FUNCTIONAL SAFETY FOR ALL GT AND ST
IN ORDER TO ENSURE:
q A HIGH STANDARD OF SAFETY AND RELIABILITY OF POWER PLANT AND COMPONENT
q A HIGH STANDARD OF SAFETY OF POWER PLANT STAFF

31

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

EXAMPLE OF GT SIL PROTECTION FUNCTIONS

1. OVERSPEED

(3 AI)
(3 DI)
(2 DI)
(2 DI)
(3 AI)
(3 DI )
(3 DI )
(3 DI)
(3 DI)
(2 DI)
(3 DI)
(3 DI)
(LOGIC+DI )
(6 AI)
(2 DI+1 AI)
(3 DI )
(4 RTD)
(4 DI)
(3 DI)
(3 DI)

2. SURGE
3. FLAME PROTECTION FOR FUEL GAS
4. FLAME PROTECTION FOR FUEL OIL
5. HIGH DIFF. PRESS. EXHAUST SYSTEM
6. GT TRIP PUSH BUTTONS
7. FIRE PROTECTION TRIP PUSH BUTTONS
8. FIRE PROTECTION
9. BOILER PROTECTION
10. ELECTRICAL PROTECTION
11. TRIP FROM AUX CONTROLLER
12. TRIP FROM FUEL CONTROLLER
13. BOILER PURGING MONITORING/FAULT
14. LOW DIFF. PRESS. SEAL OIL H2 GENERATOR
15. LOW LUBE OIL PRESSURE
16. HIGH CC ACCELERATION
17. HIGH GENERATOR COOLING AIR TEMP.
18. PREMIX DRAINS VALVES OPEN
19. TRIP FROM NO SIL PROTECTIONS
20. TRIP FROM ANCILLARY CONTROLLER
32

SIL3
SIL2
SIL3
SIL3
SIL1
SIL3
SIL3
SIL3
SIL3
SIL2
SIL2
SIL2
SIL3
SIL2
SIL2
SIL1
SIL2
SIL1
SIL3
SIL3

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

TURBINE PROTECTION AND SAFETY

33

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

TURBINE PROTECTION
AND SAFETY

34

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

SECURITY
Overview of security features:
User authentication
Role-based access control
Event logging/Audit trails
Backup/Restore
Hardened hosts
Host firewall configuration
Antivirus
Network zones
Security patch validation
Patch and service path management
Virus pattern management
Host intrusion detection
Host intrusion prevention
Network intrusion detection
Configuration change management
Disaster recovery
35

TRACK 5: ELECTRICAL & AUTOMATION FOR POWER GENERATION

SECTION 2 : TURBO MACHINERY CONTROL

THANK YOU FOR YOUR ATTENTION

36