Turbine Dynamic Simulators

Turbine Dynamic Simulators are a range of stand alone C# developed software packages that mimics various turbines dynamic behavior at a reasonably high fidelity level.

It models turbine as a lump system utilizing in house developed relatively simple robust and fast numerical methods.

There are two links at the bottom here.  A link to a simulator resembling the core features of an imaginary steam turbine with one controlled extraction. The image bellow that one is a link to a YouTube video that demonstrates some of the simulator features.

Apart from various steam turbines there are also simulators for other turbo-machines that have been mastered.  A core generic versions of gas turbine, water turbine, pump and compressor simulator have also been developed and is available to be tuned to resemble any such machine available at the market.

The simulator creates a reliable closed loop environment that can have all kind of applications.  At present it has been proven as a perfect tool for developing and pre-commissioning PLC turbine control software as well as for operators training.

The simulators are able to communicate to other Win applications, as various PLC emulators or else.  We have already executed projects with the simulator communicating to the PLC emulators namely,  Simatic S7 (a peper here) and AB CompactLogix.  That can be extended to any other PLC having it’s emulator.

Drop me a note for any additional info about this application.

EX1 STEAM TURBINE SIMULATOR
(*.RAR ARCHIEVED *.EXE FILE)

 

SOME TURBINE CONTROL BASICS

Here are few presentations covering turbine control basics.  They are focused onto the process aspect of the whole turbine control thing.

These days I see sharp young guys with a deep and detail PLC knowledge doing controls.  Sometimes I don’t see the same strength at the process control side.

Such a discrepancy is easily understood as the PLC technology is so easily accessible these days.  Just Google alone can bring you to all the nitty gritties of,  Siemens, Allan Bradley, ABB, Honeywell, and others.

However, it’s much harder to master the process control side.  It gets to you only through years of hands-on dealing with the matter itself.

Hence, here are some basic process control things related to turbine controls. It is put into three presentations already delivered to their targeted audience a year ago.  The feedback was quite positive all together.

The presentation are:

  • TURBINE CONTROLS BASICS;
  • TECHNICAL THERMODYNAMIC
    Selected Fundamentals Related To Steam Turbine Controls;
  • STEAM TURBINE CONTROLS;

Click to cover page link gets you to each of their .pdf versions.

       

STEAM TURBINE ITCC RETROFIT IN PETROKEMIJA KUTINA

 Introduction

Turbomehanika successfully retrofitted the controls for two identical steam turbine trains that are parts of the Old Nitric Acid plant in Petrokemija Kutina.  The trains are manufactured by Escher Wyss and commissioned back in 1968. Operating continuously since. Each train consists of a steam turbine, two process compressors and a gas expander all coupled together.  The steam turbine being the main drive with the expander supplementing it by expanding the process product gasses through.

The scope of the retrofit was to replace the existing steam turbine control and the compressors antisurge protection with a new PLC based Integrated Turbine Compressor Controls (ITCC) system.  Siemens SIMATIC S7-1500 PLC together with Bently Nevada Adapt 3701/55 ESD are used as the PLC hardware.

Turbomehanika have been the main contractor for the job with Arirang and Intea being subcontractors.

The Old Control System

The old control system consisted of hydraulic turbine controls and compressor antisurge protection. They were both using the same 7barg hydraulic/lube oil system.

Steam Turbine Controls had a flywheel isochronous governor operating three steam control valves actuated by a linear hydraulic servomotor.  The governor and the trip unit were both integrated together at the steam turbine front pedestrian.  The project spec required to use the existing trip device.  Separating one from each other was quite a challenging task that required gaining a deep knowledge of the Escher Wyss control concept. The governor was cut out while the trip device and the servomotor remained a part of the current system.

          

                     

Compressor Antisurge System had a control unit and the blow-off valve operated by a hydraulic servomotor.  The control unit was cut out while the blow-off valve with its servomotor remained parts of the current ITCC.

All through the recent years the customer were keep experiencing issues with the antisurge controls.  It would open the blow-off valve when it was not supposed to causing costly plant shutdowns.  While commissioning the new controls we found that in some operating modes compressors are expected to run quite near to the surge region. The old antisurge controls were most probably not being able to deal with that operating situation.

Continue reading “STEAM TURBINE ITCC RETROFIT IN PETROKEMIJA KUTINA”