PaperID:CITC

ProceedingsofThird

InternationalTurbomachineryConferenceCITC,April12,2018;ChongQing,

ReconstructionandOptimizationofControlSystemforGasTurbineRB211andCompressorUnitofLongDistanceNaturalGasPipeline

W.Y.Zhang1,X.X.Li2,Y.M.Li3

1ShenyangBlowerGroupCo., .Shenyang110869,

2PetWestPipeline ,Urumqi830013,

3BeijingConsenOil&GasEngineeringCo.,.Beijing101318,

:Longdistancenaturalgaspipelineisastrategicassetofacountry,anditssafetyandstabilityrunning hasagreatinfluenceonthenationaleconomy.Aseriesoffailureproblemsoccurredintheoperationofimportedgasturbineandcompressorunitsformanyyears,Andthefailurerateofthecontrolsystemisincreasingyearbyyear,andputtingforwardanewandmoreperfectsolution.Thecontrolsystemoftheimportedgasturbineandcompressorunitisreconstructedandoptimized.Atthesametime,tomeettherequirementsofthelongdistancenaturalgasstationonthelevelofsafetyleveloftheequipmentcontrolsystem.Practicehasprovedthatithasbettercontroleffectandapplication.

:Longdistancenaturalgaspipeline;RB211;Gasturbineandcompressorunit

Introduction

Intwenty-firstCentury,theworldenteredtheeraofnaturalgasdevelopment.Longdistancenaturalgaspipelineisastrategicassetofacountry,anditssafetyandstabilityoperationhaveagreatinfluenceonthenationaleconomy.Withtheincreaseofthelongdistancenaturalgaspipeline,thenumberofthecorrespondingcompressorunitshasalsoincreasedsubstantially.Thedrivingmodesofcompressoraremainlydividedintoelectricdrivingandgasturbinedriving[1].BecauseofitsgeographicallocationofPetro'sWesternPipelineinthewesterndesertandgobi,gasturbinedrivinghasanadvantagewhenelectricpowerwasnotavailable.Itssafetyandstabilityrunningofthegasturbineandcompressorunitisveryimportant.

Surveyoforiginalcontrolsystemofgasturbineandcompressorunit

Thegasturbinemanufacturingindustryafteryearsofresearch,developmentandcompetition, formedmonopoly.ItisthemainengineRR,HP,GE,astherepresentativeoftheaviationenginemodificationandformation;anotheristherepresentativeofheavy-dutygasturbinewithGE,,ABB[1].Among,ThegasturbineandcompressorunitofnaturalgaspipelinemanufacturedbyRR,hasindustry-leadingtechnologyandsolutionsofnaturalgaspipelinegasturbineandcompressorunit[2].Inthe20~30MWpowergradegasturbinefornaturalgaspipeline,

thereisaRB211gasturbineandcompressorunit.

Gasturbineisaconcentratedexpressionofthedevelopmentofmanyadvancedindustrialnow.Itisahighleveltechnologywithmanyintegrating.Withthedevelopmentofindustry,thedemandsforlongdistancenaturalgaspipelinetransmissionpowerandelectricpower,havedevelopedrapidlyinrecentyearsinthedomesticgasturbineindustry.Duetothemonopolyofforeigntechnology,usersarefacedwithhighmaintenancecostsandhighoperatingcosts,andthecostremainshigh.Especially,whenaseriesoffailureproblemsofthegasturbineinlongdistancenaturalgaspipeline,ithasagreatinfluenceonthenormaloperationofthewholepipeline,andthetechnicalsupportandthemaintenanceoftheforeignfactoryare ingmoreandmoredifficult.Acontrolsystemisthebrainandnervoussystemofagasturbineandcompressorunit.Itisdifferentfromthemechanicalsystem.Acontrolsystemiseasilyaffectedbythefactorofabsenceofsightandtouch.Therefore,thedomesticdemandistotryourbesttomakedomesticproduction,especiallythecontrolsystemofthegasturbineandcompressorunit.Ithas eanurgentdemandforthenaturalgaspipelinecompanies.

AccordingtostatisticsfromthePetropipelinecompressormaintenancecenterfrom2006to2010,thecontrolsystemfailureresultingindowntimeisupto630times,accountingfor34%ofthetotalnumberofshutdown.Thetimeofshutdownis5920hours,accountingfor20%ofthetotaltimeofshutdown.Thecontrolsystemfaulthas eanimportantfactorinthegasturbineandcompressorunitfailureshutdown.Moreover,theproportionofcontrolsystemfailuresincreasedfrom17.45%in2006to45.18%in2010[1].

Inviewoftheurgentdemandofthegasturbineandcompressorunitcontrolsystemmakingdomesticproduction,inwestgastransmissiontoeast,thegasturbineandcompressorunitsetisastationasanexample.RRgasturbineRB211andcompressorunitcontrolsystemasanexampletomakeadetailedysisofthespecificproblem.Basedonthetechnicalstatusoftheunitcontrolsystem,thedemandysisiscarriedout.Thereasonablecontrolsystemschemeisestablished.Thecontrolsystemfunctionisrealizedanddebugged.Throughintensivestudyofthehardwareconstruction,hardwarenetworkstructure,controlperformance,etc.Themainregulationofthecontrolsoftwareandalarmprotectionsystemsoftwarearereconstructed.

Presentsituationandexistingproblemsoforiginalcontrolsystemofthegasturbineandcompressorunit

Inwestgastransmissiontoeast,thegasturbineandcompressorunitsetisastationasanexample.RRgasturbineRB211andcompressorunitcontrolsystemasanexample.Afteroperationformanyyears,theproportionoftheunitcontrolsystemfailurehasbeenincreasingyearbyyear.ysisofthereasons,wesummarizedthemain

reasonsasfollows:

ThePLCcontroller’shardwareversionandbusversionoftheoriginalcontrolsystemconfigurationarelowerthanthecurrentversion.WhenthePLChardware

failureoccurs,therecementofthefaultmoduleinvolvesthecompatibilitybetweentheoldandthenewversions.

Electroniccomponentshaveagingcycles,andastimegoeson,electroniccomponentsbegintoage.Duringtheperiodofthehighfailure,redundancyofsomecontrolsystemshas einvalid.Thecommunicationofdatabuseshasbeeninterruptedfrequently.Theproductionaccidentscanbecausedeasily.

Aftersomanyyearsoperation,thecableofconnectingcontrolsystemandinstrumentsystemalreadyhadagingproblem.Atthetimeofpassingthesignal,failuresignaloccurseasily.Theagingcableisalsoamajorcauseoffailureofthecontrolsystem.

Manyyearsago,whentheunitcontrolsystemdesign,havealotofdifferencesofexplosion-proofrequirementsandalotofsecurityprotectionsystemandthecurrentstandards.Asthestandardscontinuetoimproveandupdate,theoriginalcontrolsystemcannotmeetspecificationrequirementsofthecurrentsafetyprotectionsystemandfireprotectionsystem.Thisisalsooneofthemajorrisksofthecurrentcontrolsystem.

Sincethedesignoftheoriginalcontrolsystemhasbeendevelopedandlimitedbythetechnicaldevelopmentlevelofthecontrolsystematthattime.Thecontrolandadjustmentofmanykeyequipmentsaredifficulttorealize.Forexample:fuelcontrolvalveloopcontrol,using7piecesofprintedcircuitboardtoachievetheprecisecontrolofthevalvefunctionadjustment.Withthegrowthoftime,thefailureratewillnaturallybegreatlyimproved.

Inordertoreducethecost,theoriginalcontrolsystemusesacontrollerwithoutsecurityauthenticationinthesystemwithmoredata.Thismakesdifferentauthenticationapplicabletodifferentsystems.Thecontrolsystemofasetofgasturbineandcompressorunitisdividedintofourprocessors.Therearemanycommunicationsignalsamongeachsystem.Withtheincreaseofthefaultpoint,itiseasytocauseahighfailurerateandthesystemisnoteasytomaintain.

Atthesametime,thecauseoftheemergencyshutdownofthegasturbineandcompressorunitandtheshortageoftheoriginalemergencyshutdowncontrolschemeareyzed.Throughtheysisoftheoriginalcontrolsystemprogram,wehavetheoptimizationandimprovement.Aimarecarriedouttoreducethechanceoffailureshutdowncausedbythehardwareofthecontrolsystemandreducethenumberofabnormalshutdown.

Aimingattheoriginalcontrolsystem’ssolutionofthegasturbineandcompressorunit

Basedontheabove,anewcontrolsystembasedonthecontrolconceptoflongdistancenaturalgaspipelinegasturbineandcompressorunitisconstructed.Thepresentsituationandexistingproblemsoftheoriginalcontrolsysteminthegasturbineandcompressorunitofthelongdistancenaturalgaspipelinearemainlydiscussed.Thecontrolsystem,networkstructure,hardware,software,pictures,etc.areredesigned.Completedthelogicofthestart-up,speedup,alarm,interlocking.

PaperID:CITC

ProceedingsofThird

InternationalTurbomachineryConferenceCITC,April12,2018;ChongQing,

Finally,thecontrolsystemreconstructionschemeisdetermined.

Anintegratedcontrolsystemrecestheoriginaldecentralizedcontrolsystem

Keepthemeasuringcontrolelementofthegasturbineandcompressorunit(site).Keepthecablesandwiresonthesitetotheoriginalcontrolsystemcabinet.Recetheoriginalcontrolsystemcabinetwithanewcontrolsystemcabinet.Theschematicdiagramofthecontrolsystembeforethereconstructionandafterthereconstructionisasfollows.

Figure1.SchematicDiagramofControlSystemBeforeandAftertheReconstruction

Threeredundantsecuritycontrollerisadoptedtoupgradethecontrolsystemhardware.Thecontroller,throughtheTUVstandardcertifiedTMRsystem,canmeettheTUV6levelandisverifiedbyISO9000.Thefault-tolerantcontrolsystemcanidentifyandcompensatethefaultsofthecontrolsystemcomponents.Allowstherepairoffaultycomponentswhilecontinuingtocompletetheassignedtaskswithoutinterruptingtheprocesscontrolandachievingon-linemaintenance.

TheoriginalcontrolsystemofthegasturbineandcompressorunitconsistsofPLC1:GTmaincontrolpart,PLC2:GTsequencecontrolsection,PLC3:gasturbineprotectionpart,PLC4:generatorunit,firecontrolsection,PLC5,loaddistributionsection,andconsistsoffiveparts.Eachpartcommunicateswitheachothertoachievethecontrolofthegasturbineandcompressorunit.Thenewstructureofthenewcontrolsystemisanintegratedstructurewhichintegratesallthepartsintoanewcontrolsystem.AlltheI/Osignalsassociatedwiththegasturbine,compressor,unitfireprotectionandunitESDsystemareenteredintothenewcontrolsystem.Allcontrolalgorithmsandcontrollogicrelatedtothegasturbine,compressor,unitfireprotectionandunitESDsystemareallcompletedwithinthesamenewcontrolsystem.Inthepast,differentPLCneedstobetransformedbycommunicationorhardwiredsignalstoformtheprogramvariablesinthesamenewcontrolsystem.Reducetheuse

ofintermediatevariables,reducethepossiblefailurepoint,andreducethefailurerate.Thenewcontrolsystemhassolvedtheproblemoflowhardwareversionofthe

PLCcontrollerintheoriginalsystemconfiguration,andimprovedthecompatibilityoftheoldandnewversionsofthefailuremodulerecement.Atthesametime,itsolvestheproblemofagingofelectroniccomponentsandthefrequentinterruptionofcommunication.Intheprocessofrebuildingthecontrolsystem,alltheconnectionandwiringofthefieldinstrumentsystemarecompleyrenewed,andthepossibilityofthefailuresignalcausedbytheleadwireiscompleysolved.

Topologicalstructureofreconstructioncontrolsystemofthegasturbineandcompressorunit

ThenetworkcommunicationrealizesredundantnetworkcommunicationbetweenthecontrollerandtheIOcard,andrealizescommunicationwiththeSCSsystem.ItwillbenetworkedwiththeOPSHMIoperatorstation,theENSHMIengineerstation,theprinter,andothercontrolsystemsSCS,asshowninfigure2.Notethatthenetworkconnectionofthecontrolsystemofthegaspipelinegasturbineandcompressorunitallowsanumberofstationssharingatransmissionlinetorandomlyaccessthetransmissionline.

Figure2.TopologicalStructureDiagramoftheControlSystemoftheGasTurbineand

CompressorUnit

Recetheoriginalfuelvalvewithanintegratedin ligentfuelvalve

ThefuelregulatingvalveusedintheoriginalgasturbineandcompressorunitistheoldproductofWOODWARD.Thevalvecontrolneedstobeequippedwith7

auxiliarymodulestowork.Theoriginalcontrolsystemfuelcontrolvalveloopcontrol,using7piecesofprintedcircuitboardtoachievetheprecisecontrolofthevalvefunctionadjustment.Failurerateishigher.

InthenewsystemwillusethelatestfuelgascontrolvalveGS16WOODWARD.Theupdatedfuelcontrolvalveismechanicalandelectricalcontrolintegratedinligentvalve,withoutexternalauxiliarycard,itselfcomeswithinligentadjustmentfunction.Valvecontrolloopissimple,withoutcalibration,highreliability,

self-cleaningandotherfeatures[3].

Figure3.GS16WiringDiagram

Inligentfuelcontrolvalveandthegasturbineandcompressorunitcontrolsystemhaveachievedgoodcoordinationandadjustment,atthesiteshowedstableperformance,fastresponseandothersuperiorperformance.

Figure4.FuelControlValveSiteOperationEffectDiagram

Safetydesignofcontrolsystem

Throughthesystemsecuritylevelcalculation,itmeetthesystemsecuritylevelthreelevelrequirements.Atthesametime,trytoimprovethesecuritylevelofotherintegratedhardwareinthecontrolcabinetsoastomeetthelatestinternationalsecuritystandards.Explosionproofandsurgeproofprotectorsarealsoadded.

Thegasturbineandcompressorunithasahighdemandforsafetyprotection.Thereconstructioncontrolsystemimprovesthesafetyoftheequipment.Reduceaccidentsanddowntimeduringequipmentproductionandincreaseoutput.Itcanbeeasilyintegratedintoexistingsystemsandfuturesystems,andhasgoodcompatibility.Comprehensivehardwarediagnosisandsystemdiagnosis,diagnosticcoverageofmorethan90%.Ithashighsecurityandhighavailability.Thereconstructionoflongdistancenaturalgaspipeline,thegasturbineandcompressorunitcontrolsystem,hadagoodrealizationoftheunitmonitoringandcontrol.Practicehasprovedthatthesiteoperationisingoodcondition.

Summary

Withtheadvancedredundancycontrolsystem,