Al Qaim IRAQ - Steam Turbines Control System AUTOMATION

Transcription

1 Al Qaim IRAQ - Steam Turbines Control System AUTOMATION

2 Plant Overview State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System About the Plant SCP chemical complex started production in It consists of integrated and interrelated plants to produce different kinds of phosphate fertilizers as a final product. These plants are: ore beneficiation plant U100, sulfuric acid plant U200, phosphoric acid plant U300, utilities plant U620, fertilizers plants U400, ammonia plant U451, fluorine salts plant U500, materials handling plant. Iraq Ministry of Industry and Minerals State Company for Phosphate Products Main SCP products are: Fluorine salts Ammonia Sulfuric acid Phosphoric acid concentration 54% (P 2 O 5 ) Center fertilizer phosphate (TSP) Single phosphate fertilizer ammonia (MAP) Composite fertilizer (NP, NPK). About SCP Main objectives of the company are: exploration phosphate deposits beneficiation of phosphate ores production of phosphate fertilizers production of compound fertilizers production of by-products.

3 About the Project State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System The Project "Rehabilitation of two steam turbines TG1 and TG2" project in Al Qaim Fertilizer Complex Power Station (Unit 620) was started in June Main parts of the original, old control system: steam turbine governors (BBC Turboturn 4), protection (BBC relay cubicles) and control panel. The purpose was to restore 2x14MW power generating capacity required for increasing of plant production and enabling overhauls of other plant sections. Main contractor was INGRA M.E. d.o.o. - Zagreb-Croatia. Site acceptance and successful handover were completed in April Site works, including commissioning and start-up of the turbines and automation system, were completed by two INTEA engineers within two months. Scope Scope of the project was: overhaul of the turbines and instrumentation, replacement of turbines control system.

4 State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System New Steam Turbines Control System - Main Parts Al Qaim Steam Turbines Control System is used for governing and protection of steam turbines. Main parts are: Two Steam Turbines Controller Cabinets (for TG1 and TG2) Two Operator Stations Engineering Station Communication Networks Printers Uninterruptible Power Supply (UPS) Steam Turbine Controller Cabinet contains 2 units ABB AdvantController 160 Enginering Station PC notebook computer with Microsoft Windows, 17" monitor and ABB 800xA Engineering Workplace system software. Printers Two A4 laser printers for alarm and events printouts, report printouts, e.t.c. One A3 color ink jet printer - used for printouts of process graphics. Communication Networks ABB AdvantFieldbus 100 network is used for communication between process controllers and operator stations. Ethernet network is used for communication between operator stations and printers. Operator Station PC workstation (desktop computer) with AF100 communication module and ABB 800xA Operator Workplace system software. UPS Standalone UPS 230VAC for each ABB Operator Station,

5 State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System New Steam Turbine Control System - Configuration / Block Diagram Plant Netw ork (Ethernet) Operator Workplace 1 Operator Workplace 2 Color InkJet Printer (A3) Engineering Station Laser Printer (A4) UPS 230VAC Control Netw ork AF100 Laser Printer (A4) UPS 230VAC Advant Controller 160 Steam Turbine TG1 Steam Turbine TG2 I/O ~200 I/O ~200 AC160 Governor AC160 Protection AC160 Governor AC160 Protection

6 Steam Turbine Controller Cabinet State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System Overview Each Steam Turbine's control system is enclosed in its own cabinet (1600x2100x600 mm), containing: two ABB Advant Controller 160 units (governor and protection), power supply, network equipment and I/O modules. Each cubicle is equipped with all necessary terminals and interposing relays, wiring ducts, earth bars, lighting, anti-condensation heater and ventilation, 230V/50Hz power socket, door limit switch and is completely internally wired before the delivery. Ingress protection is IP54. Redundancy The whole system is redundant. In case of a problem or failure of any system device, another one with the same functionality automatically takes over and ensures continuation of normal system operation. For example, if one operator stations fails, operator can continue controlling both steam turbines using the other operator station.

7 State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System Steam Turbine Control System - Main Parts Turbine Governor Each "Turbine Governor" AC160 controller has the following configuration: redundant processor (CPU), redundant network equipment, 32 DI (digital input) signals (24 VDC), 16 DO (digital output) signals (relay contacts), 32 AI (analog input) signals (4-20mA), 8 AO (analog output) signals (0-20mA, 0-10V), 3 DP (pulse input) signals for speed measurement. Turbine Governor includes software functions of speed governor, overspeed protection, run-up and loading program devices, package of pressure controllers and limiters. Governor controller is basically controlling Control Valves (Live Steam and Cross-over). The Governor operates on one ABB Advant Controller 160, with data bus system and redundant CPU. Overspeed protection is a two-out-of-three system that is independent of the data bus system.

8 State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System Steam Turbine Control System - Main Parts Turbine Protection Each "Turbine Protection" AC160 controller has the following configuration: redundant processor (CPU), redundant network equipment, 64 DI (digital input) signals (24 VDC), 32 DO (digital output) signals (relay contacts), 12 AI (analog input) signals (4-20mA). Turbine Protection system operates on ABB Advant Controller 160 with data bus system and redundant CPU, separated from the Governor controller. Protection controller is controlling Main Stop Valve. Redundant Control Network supports communication betwen Steam Turbine Controllers and Operator Stations.

9 Operator's Screen Example State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System

10 Operator's Screen Example State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System

11 lntea - Delivery Scope State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System Engineering Services Project management Design engineering control system functional design specification software design specification site/construction related drawings and instructions control system documentation: cabinet construction drawings, database and program listings, wiring diagrams, operating and maintenance manuals, etc. FAT procedures onsite works descriptions and procedures final as-built documentation Application engineering application engineering of steam turbine process controllers application engineering of steam turbine operator stations internal test in INTEA premises HW manufacturing and assembling assembling of steam turbine controller cabinets FAT During the Factory acceptance test all necessary tests were carried out to verify that the complete system delivery is in accordance with contract specification and requirements. The tests were performed in accordance with INTEA standard test procedures and test protocols. FAT lasted one week. Offsite training Training course in Zagreb, with duration of 2 weeks, for 3 trainees. Each training session consisted of the following standard training courses: Course CP001: STCS Operation, Course CP002: STCS Process Controller Configuration and Maintenance, Course CP003: STCS Operator Station Configuration and Maintenance. Site works supervision of old equipment dismantling erection and installation of new equipment supervision of cabling and wiring to new steam turbine controller cabinets supervision of power cabling from UPS cabinets to new controller cabinets check of instruments connected to steam turbine control system check of control devices controlled by steam steam turbine control system check of related field wiring - loop checks commissioning start-up Hardware Delivery Two Steam Turbine Controller Cabinets (for TG1 and TG2) Two Operator Stations Engineering Station Communication Networks Printers Uninterruptible Power Supply (UPS)

12 State Company for Phosphate - Al Qaim Fertilizer Complex Pow er Station (Unit 620) - Steam Turbines Control System