TURBINE TRIP CASE STUDY (120 MW)

Presentation Title
Presentation Subtitle

VIJAYANT RANJAN

All India Seminar On Instrumentation and Process Control- 28th. Nov

Organized by Institution of EngineersJamshedpur

1

TOPICS TO COVER

INTRODUCTION TO TURBINE CONTROL BASIC CONCEPT OF TMR TMR IMPLEMENTATION CASE STUDY CORRECTIVE ACTION CONCLUSION

Introduction to Turbine control

Turbine Control consists of two major sections : a) Governing Control by Electro-Hydraulic Turbine Control (EHTC) b) Turbine Protection (TP)

Both the sections are implemented in Triple Module Redundancy (TMR) configuration in Pro-control Ver.-P13/42 provided by BHEL (original designer ABB)
This case study is based on Turbine Protection

TOPICS TO COVER

INTRODUCTION TO TURBINE CONTROL BASIC CONCEPT OF TRIPPLE MODULE REDUNDANCY (TMR) TMR IMPLEMENTATION CASE STUDY CORRECTIVE ACTION CONCLUSION

BASIC CONCEPT OF TRIPPLE MODULE REDUNDANCY (TMR)

In general: NMR (always odd number. eg. TMR, 5MR) Triplicates the hardware and perform a majority vote to determine the output of the system If one of the modules becomes faulty, the 2 remaining fault-free modules mask the results of the faulty module when the majority vote is performed
MODULE 1

MODULE 2

MODULE 3

TMR IMPLEMENTATION SIGNAL FROM FIELD IS ACQUIRED FIRST IN SIGNAL DISTRIBUTION PANEL, FROM WHERE THESE SIGNALS ARE DISTRIBUTED TO INDEPENDENT TMR PANELS FOR EXAMPLE :

MAIN STEAM TEMPERATURE

-1

SIGNAL CONDITIONING PANEL

TMR

-1

TMR

-2

TMR

-3 2

MAIN STEAM TEMPERATURE SIGNAL CONDITIONING PANEL

TMR

-1

TMR

-2

TMR

-3 -3

MAIN STEAM TEMPERATURE SIGNAL CONDITIONING PANEL

TMR

-1

TMR

-2

TMR

-3

TMR IMPLEMENTATION IN EHTC & PROTECTION

TMR # 1

I/P - 1 I/P - 2 I/P - 3

2/3

TMR # 2

I/P - 1 I/P - 2 I/P - 3

FOR FINAL TRIPPING / CONTROL

2/3

2/3

TMR # 3

I/P - 1 I/P - 2 I/P - 3

2/3

TOPICS TO COVER

CONFIGURATION OF TURBINE CONTROL IN PRO-CONTROL V.P13 INTRODUCTION TO TMR TMR PHILOSOPHY CASE STUDY CORRECTIVE ACTION CONCLUSION

Case study :
I) Date : 19/11/08 Time : 18:30 Hrs First tripping took place on 19/11/08, without any alarm or indication. The only alarms that appeared were:
  

Turbine Trip 1 Turbine Trip 2 Turbine Trip 3 The plant was therefore resynchronized after confirming that everything was normal both in field as well as in system.

II) Date : 24/11/08

Time : 04:45 Hrs

The second tripping took place again on 24/11/08 without any prior indication. This time it was decided to investigate the turbine trip alarms itself since there was no other clue available. During this process, it was suspected that there were automatic turbine shut-down signals coming from ATRS panel, which if get simulated may lower down the Load and the Speed set point.

Contd..

One of the trends also showed that there was lowering of MW set point, Speed set point followed by the turbine tripping. However, at that point of time, there was no load rejection in the electrical power system. Therefore, the signals coming from ATRS panel to EHTC common station had been bypassed so as to ensure that no tripping is initiated from ATRS panel.

III) Date : 25/11/08

Time : 03:45 Hrs

The third tripping took place in a similar fashion on 25/11/08. In order to eliminate some of the probable causes of the tripping, it was decided to change some of the cards which were common to turbine control. In this regard, Bus-traffic director (FV01) sitting on turbine IPB and bus-coupler (BK02) of CCA02 and CCA05 (ATRS panels) were changed.
Contd.

IV)

Date : 28/11/08

Time : 05:45 Hrs

Because of recurring unit trippings, it was finally decided to take 8 hours shut-down of the unit to analyze the root cause of the problem. The team of engineers did a Why-Why Analysis. The findings are as follows : 1) Why did the plant trip? = Because turbine trip command was issued from TMR panels. 2) Why did TMR issue trip command? = a) Because of change in process parameters. = b) Because of element mal-operation. = c) Because of signal simulation by I/O cards.
Contd.

3) =

Why did the alarm not appear if the element had mal-operated? The alarm is configured for 2 out of 3 logic. The alarm shall not come if only 1 element mal-operates. Why the alarm is not configured for single element mal-operation? OEM design gap. Why would the card simulate fault signals? Inherent problem of BHEL supplied I/O cards. These cards simulate the fault signals on its own, thereby causing a trip signal to initiate in Contd. a TMR.

4) = 5) =

7)

Why would the unit trip on single TMR trip signal?

The plant shall not trip on signal TMR trip signal. But if one of the element has gone faulty, the protection logic shall change from 2/3 to in all the three TMR panels. Now, if any of the cards simulates a fault signal, it shall trip the TMR. If the same simulation takes place in another TMR panel (before the trip signal is reset), it shall TRIP the turbine without generating any alarm.

Contd.

TMR # 1

Signal simulation I/P - 1 I/P - 2 I/P - 3

Trip

1/2 2/3

TMR # 2

Signal simulation I/P - 1 I/P - 2 I/P - 3

Trip
TURBINR TRIP

1/2 2/3

2/3

TMR # 3

I/P - 1 I/P - 2 I/P - 3

1/2 2/3

TOPICS TO COVER

CONFIGURATION OF TURBINE CONTROL IN PRO-CONTROL V.P13 INTRODUCTION TO TMR TMR PHILOSOPHY CASE STUDY CORRECTIVE ACTION CONCLUSION

1)

TRIP CIRCUIT MODIFICATION An additional circuit was introduced in the turbine trip logic which would reset the TMR trip signal, in case the trip signal is issued from a single TMR panel. However, before resetting the trip signal, the logic shall also ensure that the other TMR panels are in healthy condition. This is done to avoid reseting the trip logic during actual process trip command.

2)

ALARM CIRCUIT MODIFICATION 2/3 logic was implemented in the alarm circuit. Under such condition, a corrective action so as to replace a faulty element before the trip occurs cannot be taken. Also, it does not give any information for the post-trip analysis. To overcome these problems, 2/3 alarm logic is modified into an OR gate circuit.

Turbine trip command from

Turbine Section Boiler Section Generator Section
MAN RESET

RSR R S

TURBINE TRIP

Turbine Trip Circuit (Before Modification)

Applicable to all the three TMR panels

C.O. SUPPLY OFF C.O. EMGY PB PRSD EMERGENCY PB PRSD FIRE PROT HP/IPSHFT VIB; LP SHFT VIB; GEN BRG VIB COND PR HI MS TEMP HI/LO LUB OIL PR/LVL LO BOILER TRIP GEN ELECT PROT AXIAL SHIFT TSLLE

O R

TURBINE TRIP

TURBINE TRIP

BOTH FDF OFF BOTH IDF OFF EMERGENCY TRIP FUR PR V LO (2/3) FUR PR V HI (2/3) DRM LVL V HI (2/3) DRM LVL V LO (2/3) AIR FLOW < 30% RHP TRIP 220 V DC NOT AVAIL FLAME FAILURE TRIP LOSS OF ALL FUEL

M F T
BOILER TRIP

BOILER TRIP

Process trip command from

Turbine Section Boiler Section Generator Section O R RSR R S

TURBINE TRIP

Modified circuit (Auto reset)

TRIP CH-A OPTD TMR 2 NOT TRIP TMR 3 NOT TRIP

A N D

T I M 20 SEC E R

MAN RESET

O R
3 SEC

Turbine Trip Circuit (After Modification)

Process alarm from

TMR # 1 TMR # 2 TMR # 3

2/3

Alarm Circuit (Before Modification)

Process alarm from

TMR # 1 TMR # 2 TMR # 3

O R

Alarm Circuit (After Modification)

Contd..

TOPICS TO COVER

CONFIGURATION OF TURBINE CONTROL IN PRO-CONTROL V.P13 INTRODUCTION TO TMR TMR PHILOSOPHY CASE STUDY CORRECTIVE ACTION CONCLUSION

CONCLUSION Upon rectification of the problem, the team discussed about some of the similar trippings in past. However, because of insufficient alarm configuration, root cause fault analysis could not be carried out correctly. After the analysis, the root cause of the problem was identified to be spurious fault simulation by I/O cards. This was also confirmed later by BHEL that this is an inherent problem of the Pro-control I/O cards and therefore cannot be eliminated at site. Also, these cards are not intelligent enough for self diagnosis. However, to improve the reliability of the units, the corrective actions were taken at logic level to eliminate the tripping because of fault simulation of cards. The same modifications shall be carried out in other units as and when opportunity comes.

7 6

O u t a g e s

5 4 3 2 1 0

The unit has not tripped since modification. Though the turbine trip signal was issued from single TMR panel, it was auto reseted before another TMR panel could initiate the trip signal.

4
YTD Yr FY07 Yr FY08 FY10'No v 1 4 6 0 0 0 0 0 0 0 0 Apr'09 May'09 June'09 Jul'09 Aug'09 Sept'09 Oct'09

FY08 (Actual) FY 09 (Actual FY 07 (Actual) YTD FY10

No. of unplanned outages due to Card fault simulation. 2