Published on March 11, 2014
One Solution for Simulation of Steam Turbine Power Upon 210MW Vesna Petkovski, Nikola Krajnović, Miloš Stanković, Nebojša Radmilović Institute ’’Mihajlo Pupin’’, Belgrade, Serbia www.pupin.rs Željko Gagić Thermal Power Plant ’’Nikola Tesla A’’, Obrenovac , Serbia www.tent.rs
Idea About Simulator The global industry trend is to reduce all costs regardless of their origin. In electrical industry, one part of solutions for reducing the number of plant dropouts is system optimization and good personnel training. • Simulators and training systems represent a modern method of training staff that operates in various sectors of a power plant (production, maintenance etc.) An inadequate training often leads to non- professional reactions in critical situations. • Some of the advantages of such training systems are the possibility of a thorough analysis of a recorded event, the possibility to set the simulator to a state preceding a turbine trip or another critical situation and the analysis of various influences on the plants stability. • The price of the insurance policy significantly diminishes if the personnel have been trained on a certified training system.
Simulator Usage The turbine simulator consists of several hardware and software components and it is used for testing of turbine governor and turbine protection: • in the phase of installation • during design and optimization of the algorithm • for factory acceptance test • during testing and putting into operation a complete integrated system on facility • training of staff with the new system of regulation before the first turbine startup
Steam Turbine Qshs Pcrs Pshs Phrs Plpbp Qlpbp Qhpbp Low pressure bypass station High pressure bypass station Start up bypass station Condenser High pressure chamber Inter- mediate pressure chamber Low pressure chamber 1 Low pressure chamber 2 Reheater Boiler (superheater) To Generator Shaft Qlpt Pacs N IP valves IP valvesHP valves HP valves QB, PB Condensate steam turbine of 350MW, type 18-K-348, manufacturer ZAMECH (Elblag, Poland) is considered for the modeling approach. This turbine installed at Unit B2 of TPP “Kostolac B”, Drmno, Serbia. Turbine parameters: Nominal power 350MW Rated speed 3000rpm Steam pressure in front of turbine 180bar Intermediate pressure 42.4bar Pressure behind LP chamber 6bar
Generator SG Generator P Generator breaker Main circuit breaker Auxiliary unit breaker Auxiliaryunitgrid Networkline From Turbine Shaft Unit transformer Auxiliary unit transformer Generator (nominal voltage 410kV, nominal power P = 410MW, cosφ=0.85) over generator breaker, unit transformer (nominal power 410MW, incoming voltage 410kV, outgoing voltage 22kV) and main circuit breaker is connected with network. Auxiliary unit transformer is connected at generator voltage.
Turbine Model Turbine model is designed so that it can fully complete simulation of important real process parameters. Overall model contains: Boiler model, HP, LP and start-up bypass station model, Electro-hydraulic servo drive, Model of control valves, Reheter model, Turbine mechanical power model, Generator model
Turbine Model Structure of turbine-generator model
• Boiler model of this type is developed and used only for turbo-plant simulation and it considered that the pressure at the outlet of boiler PB and steam production QB are constant values. Change in pressure Pshs or flow Qshs in front of HP turbine, depends only on change in position of control HP valve and flow through HP bypass station Turbine Model – boiler with HP valves & HP ByPass
Turbine Model – steam flow characteristic 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 HP/IP valves position [%] [%] high-pressure flow characteristic intermediate-pressure flow characteristic Nonlinear functions define the flow of steam through HP valves depending on the HP valve position. Similarly, flow of steam through IP valves is showed also These nonlinear function are the most important part of model, since it defines steam flow linearization through turbine. Values of these functions are obtained from measurements of steam flow and valve position, taken during different turbine operating conditions.
HP bypass station Turbine Model – other turbine parts Electro-hydraulic drive model Reheater model with IP valves and LP bypass stationStart-up bypass station
Turbine Model – generator & operating modes Control logic for genertator operating modes
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 500 1000 1500 2000 2500 3000 - max absolute error 1.8687% - mean absolute error 0.37665% turbine speed SIM turbine speed ARH 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0 10 20 30 40 50 time [s] position[%] HP valve position IP valve position LP bypass position The comparison of the obtained parameters by the simulation showed satisfactory matching with real data. Increasing turbine speed from a cold state with position of HP valves, IP valves and LP bypass station Results – model VS real plant (verification)
Increasing turbine power after sinhronization to power grid Results – model VS real plant (verification) 0.9 0.95 1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4 x 10 4 0 20 40 60 80 100 120 140 160 180 200 time [s] electricpower[MW] electric power SIM electric power ARH
Comparative analysis of simulated and real turbine speed during turbine droopout and speed reducing Results – model VS real plant (verification) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 x 10 4 0 500 1000 1500 2000 2500 3000 time [s] speed[rpm] - max absolute error 1.9185% - mean absolute error 0.56801% turbine speed SIM turbine speed ARH
Hardware – for real-time simulations To operate the model in real time it is used National Instruments PXI-1044 platform which consists of: • Embedded controller PXI-8105, that satisfies demands for real-time work. The used operating system is LabView® 2009 Real Time v.9.0. • Multi-function acquisition card M-Series, type PXI-6289 has four 16-bit analog outputs, 16 differential analog inputs, 48 digital bidirectional channels and two pulse outputs with maximum output frequency of 80MHz. • Multi-function acquisition card M-Series, type PXI-6723 has 32 analogue outputs, 8 digital bidirectional channels and two pulse outputs with maximum output frequency of 20MHz. Simulator user interface is situated on the computer, PC with MS Windows® operating system, which is separated from the real-time controller and it communicates with the real-time controller through a local area network.
Simulator Connection Turbine governor & Simulator Turbine governor
Opeartation Panel for Simulation The operation panel is used to: • start or stop the real-time simulation • set some digital or analog input variables • turn on certain system parts (bypass stations, generator breaker,...) • monitoring simulator output signals such as electric power, rotation speed of the turbine or steam turbine pressure
Conclusion • Complete training system realistically reflects the behavior of the real system in all operating modes, • Simulator enables training and testing of the plant personnel without any risk to the actual turbine equipment and it is possible to simulate certain incidental states that rarely occur, • More convenient to train staff how to behave in critical situations in the simulator than on real plant, • This model can be integrated into other simulator tools, • Further development of the described simulator will be reflected in the modeling of mechanical measurements on the turbine (vibrations and shifts) and the temperature of the material in some parts of turbine.
Thanks for attention You may contact us at: • Vesna Petkovski, Researcher firstname.lastname@example.org • Nikola Krajnović , Researcher email@example.com • Miloš Stanković , Researcher firstname.lastname@example.org • Nebojša Radmilović , Researcher email@example.com • Željko Gagić, Main engineer for turbine facility firstname.lastname@example.org
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