TECH LIBRARY 1 Func Desc Instrux - Control - ACGAL020S000002_B.pdf

System Design Specification Page 1 of 24 ACGAL020S000002_B.doc

Project: ACGAL020 Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

System Design Specification

ACGAL020S000002

Call Henry Inc.

Allison 501-KB5

South Vandenberg Power Plant

Vandenberg AFB, CA USA

Revision Date Reason Approved

A 30 Jan 2017 Post – FAT Revisions S.Taylor

B 13 Sept 2017 As Commissioned S.Taylor

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Customer: Call Henry Inc.

Printed 2017 / Printed in the USA

Copyright 2017, EthosEnergy Group LLC

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System Design Specification Page 3 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

Table of Contents

1 INTRODUCTION

1.1 HMI OVERVIEW

1.2 COMMUNICATIONS DESIGN LAYOUT

2 PLANT CONTROL SYSTEMS

2.1 OVERVIEW OF CONTROL FUNCTIONS

2.2 GOVERNOR / SEQUENCER INTERFACES

3 ENGINE GOVERNOR DEFINITION

3.1 FUEL DEMAND SELECTION

3.2 START-UP CONTROL/ACCELERATION SCHEDULE

3.3 DECELERATION SCHEDULE

3.4 TEMPERATURE LIMITING

3.5 SPEED GOVERNING

3.5.1 Off-Line

3.5.2 On-Line

3.6 KW LOADSHARING

3.6.1 Isolated Mode

3.6.2 Utility Mode

3.7 COMBINATION GENERATOR CONTROL MODULE OPERATION

3.7.1 Interfaces with Governor

3.7.2 AVR Functionality

3.8 FUEL VALVE OPERATION

3.9 FUEL CHANGEOVER

3.10 SYNCHRONIZATION

3.11 KW LIMITING MODE

3.12 NORMAL SHUTDOWN SEQUENCE

3.13 UNIT EMERGENCY SHUTDOWN OPERATION

4 CONTROL SETPOINTS

4.1 CONTROL VALUES SUMMARY

5 PLANT PROTECTION SYSTEMS

5.1 HARDWIRED EMERGENCY SHUTDOWN CHAIN

5.2 ANALOG INPUT FAULT MONITORING

5.3 SPEED FAULT DETECTION

5.4 OTHER ALARMS AND SHUTDOWNS

5.5 CONTROL INTERNAL SYSTEM FAULT DETECTION

5.6 ALARM ACKNOWLEDGE & RESET

6 COMMUNICATIONS

APPENDEX A. SYSTEM ALARMS AND SHUTDOWNS

A.1 HARDWARE FAULTS

A.2 CONTROL SYSTEM ALARMS

A.3 TURBINE SHUTDOWNS

A.4 TURBINE EVENTS

System Design Specification Page 4 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

1 Introduction This document describes system number ACGAL020 which was sold to Call Henry Inc.

located at the South Vandenberg Power Plant at the Vandenberg AFB, CA USA. The control system replaces the Five (5) Woodward based control systems and the associated GE Series Six sequencers for their Allison 501-KB5 Gas Turbine Generator sets.

The fuel governor software algorithms used by the new Allen Bradley ControlLogix controller are based upon the existing site fuel control software developed by EthosEnergy (then Wood Group), EthosEnergy’s Energy Allison 501 Controller software algorithms, and the existing Series Six sequencer code.

The scope of the project was a direct translation of the existing functionality into a new Rockwell ControlLogix based platform. This includes new HMI computers to replace the functionality of the existing CiTect Fuel Control HMI displays.

Since the new system is, as closely as possible, a direct replication of the existing system, the existing system descriptions of operation remain valid. This document is intended to highlight the differences in the systems.

All field devices and ancillary controls including fuel valves, generator protection, vibration monitoring, etc., have been retained in their entirety. The control philosophy of monitoring a single Turbine Outlet Temperature (TOT) thermocouple and calculation of Turbine Inlet Temperature (TIT) has been retained.

1.1 HMI Overview

The HMI utilizes Rockwell FactoryTalk View SETM software on two workstations. The HMI client will communicate directly with its corresponding PLC over the plant network.

Refer to ACGAL020S000003 for further information on the HMI system operation and screens.

The HMI computers are also loaded with Engineering Tools to maintain or modify the system. This includes the Rockwell Studio 5000 and FactoryTalk View Studio software required to monitor or edit the Turbine Control and to edit the HMI application software, respectively, and the EthosEnergy SIMCFG software to configure the Speed Input Module.

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Customer: Call Henry Inc.

Site: South Vandenberg Power Plant

1.2 Communications Design Layout

System Design Specification Page 6 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

2 Plant Control Systems The new system consists of three chassis. The first, Rack 1 replaces the Series Six CPU and IO Rack that is located in the metering cabinet in the main control room. The second, Rack 2, replaces the Series Six IO rack that is located on the Turbine enclosure.

In Rack 2, handshaking signals between the Series Six and the ATLAS fuel control are no longer required as the systems are integrated so these signals have been made spares.

The third, Rack 3 replicates the ATLAS Turbine Fuel Control IO with the exception of the DI/DO modules which accomplished handshaking between the Turbine Fuel Control and the Series Six sequencer.

One DI signal, Droop/Isoch Switch, and two DO signals the ISOCH RELAY – ISOCH TO REAL POWER SENSOR and the LOAD SHARE RELAY – LOADSHARE ENABLE have been moved from the Turbine Fuel control to the Sequencer Rack 2 IO. During installation it will be decided whether existing spare wires (which were previously used for handshaking) will be used between the Rack 2 IO and the Relays associated with Rack 3 or whether new wires will be pulled. The site has confirmed that a conduit exists between the two locations that that it would be simple to pull new wire through the short straight conduit run.

For the initial installations, the existing Woodward Real Power Sensor will be retained to provide isochronous load sharing interfaces as well as compatibility with the existing SPM synchronizer. After all units are retrofit with the new CGCMs, it will be possible to replace that functionality with the CGCM and to remove the Real Power Sensor hardware. Rerouting of the loadsharing lines and modification of the control software would be required to accomplish this.

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Customer: Call Henry Inc.

2.1 Overview of Control Functions

The controller performs all of the necessary gas turbine governing during turbine start-up, power generation, and shutdown. Turbine operations include motoring (cranking), ignition & firing, acceleration, speed governing, TIT limiting and KW limiting.

The principal functions provided by the controller are:

• Start Fuel Control using total fuel demand (position) feedback

• Turbine Inlet Temperature Calculation

• Turbine Inlet Temperature Control and Limiting

• Speed Governor Control

• Maximum/Minimum Fuel Limitation

• Fuel Valve Position Control (w/Feedback)

• Isochronous with Load Sharing and Droop Mode Configurations

• Alarm and Fault Monitoring

• KW Limiting

Rack 3

Turbine Fuel

Control

IO

LVDT

Interface

Real Power Sensor

Independent Overspeed Switch

CIT Sensor – AD590 (2)

Transformers and Burden Resistors PT’S and CT’S

KW Load Signal

Speed Bias From SPM - A

Load Sharing Signal (to other units)

TOT Thermocouple

Speed MPU (2)

Load Sharing (from other units)

LVDT

Interface

Gas FMV LVDT Excitation Gas FMV LVDT Return Liquid FMV LVDT Excitation Liquid FMV LVDT Return

24VDC Breaker Fusing & Distribution

Independent O.S. Trip (STB)

Ethernet To HMI

Functional Block Diagram Functional Block Diagram Vandenberg Air Force Base Vandenberg Air Force Base

Allison 501 Control Conversion

ATLAS

Functionality

Speed Bias

Speed Input Module

Rack 2

Turbine Skid Sequencer

IO

Rack 1

CPU, Comms, and Metering

Cabinet Sequencer

IO

Annunciators and indicators Remote Selector Switches and Pushbuttons

Flow Meters Local Selector Switches and Pushbuttons Fuel System solenoids

Starter Interface Sequence Relays

Series Six Functionality

On-Skid Pressure, Level, and Status Switches

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The governor software provides an output fuel demand with selection logic being used to determine which loop should be in control. For maximum flexibility schedules and setpoints can be “tuned” from the Rockwell Studio5000 software. The governor software also provides alarm and shutdown monitoring of all signal transducers. Protection against exceeding the turbine operating parameters is provided.

2.2 Governor / Sequencer interfaces

The fuel control requires several key sequencer indications and provides information back to the sequence. Inputs include: Emergency Stop, Speed Setpoint Raise, Lower and Reset Commands, Temp (TIT) Setpoint Raise, Lower and Reset Commands, Isoch / Droop Mode selection, Fuel Transfer commands, Underspeed Override, Alarm / Shutdown Reset and Overspeed Reset. Outputs from the governor include: Various Speed switches and Temp switches, Fuel On (for both liquid and gas), and Control Trip. See Appendix A at the end of this section for more detail

The Sequencer Ladder Logic Code has been translated to match the functionality from the original sequencer code provided by the site. Since the functionality was not modified, the original Williams and Lane Description and Sequence of Operation documentation remains the functional definition for this section of the code.

The sequencer is responsible for:

• Ready to Start Checks

• Start Initiation

• Fuel Changeover Selection

• Water Injection Control

• Auto/Manual Synchronization Selection

• Normal Stop

• Emergency Shutdowns not related to Governor functions

• Alarm Detection and Annunciation

During start-up the governor is responsible for:

• Light-off and start fuel control

• Flame Detection and Stagnation Checks

• Fuel Changeover Ramping

• Emergency Shutdowns as determined by Turbine parameters

• Alarm Detection and Annunciation

System Design Specification Page 9 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

3 Engine Governor Definition The controller provides a comprehensive fuel control system, equipped with four non-interactive controllers. The applicable controllers to control the speed and power output for all generator sets have been configured.

Start Fuel/Accel Controller

Speed (N1) Governor kW Limiter

N1 Decel Schedule (Disabled)

TIT Limiter

HIGHEST

WINS

Fuel Transfer Logic

Liquid/Gas Valve

Setpoints

LOWEST

WINS

Gas Actuator Driver

Liquid Actuator Driver

Figure 3-1: Fuel Demand Selection Diagram

3.1 Fuel Demand Selection

The gas turbine governor software algorithms provide start-up control, temperature limiting, acceleration limiting, speed governing, KW limiting, deceleration limiting (currently disabled) and maximum fuel limiting as shown in Figure 2-1. The output fuel demands generated by each of these governors/limiters are compared to each other.

First, the lowest of the fuel demands resulting from this comparison is selected as the winning fuel demand. This fuel demand is compared to the deceleration limiter fuel demand and the highest fuel demand is selected and is sent to the fuel transfer logic which produces the fuel valve actuator signal.

Proportional and integral gain adjustments are provided in the controller software for each mode (as appropriate) to allow for tuning of the control system to meet site-operating conditions.

3.2 Start-Up Control/Acceleration Schedule

The fuel limiter controller is responsible for the closed-loop fuel scheduling from start initiation through to speed governing. The controller setpoint is a function of N1 Speed biased by TIT. The sum of both valve position signals determines the process input for the controller. The schedule shown in Figure 3-2 is taken from an Allison 501-KB5 specification. It depicts the relationship between N1 (NGG) Speed and fuel demand in pounds per hour (pph). Figure 3-3 depicts the fuel limiter setpoint schedule of the relationship between N1 Speed and fuel valve position demand.

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Accel Schedule

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000

NGG Speed (rpm)

Fuel Demand (pph)

Figure 3-2: Acceleration Control Scheme (Typical 501-KB5)

Figure 3-3: Fuel Limiter Schedule

3.3 Deceleration Schedule

The deceleration schedule provides a minimum fuel limit, scheduled against N1, protecting against gas generator flameout. Since the GT400 did not provide a ecal schedule function this feature is disabled. However should it be determined that this featured is desired the control can be tuned (no programming changed needed) to enable the schedule. Figure 3-4 depicts the schedule currently in place that can be enabled by changing the constant in _160_HSS_LSS Sheet 1 SCL_01.InEUMax from -0.2 to 100 (%). This block converts the fuel flow in PPH to percent fuel valve demand.

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Customer: Call Henry Inc.

Figure 3-4: Decel Schedule

3.4 Temperature Limiting

In order to prevent turbine overheating and to prolong the life of the turbine, the controller continuously monitors the turbine outlet temperature (TOT) thermocouple.

The controller is configured to calculate the turbine inlet temperature (TIT) using a proprietary algorithm. This function was originally done in the Allison Speed / Temp box. Calculated TIT (CTIT) was then supplied to the GT400 controller. In addition to TOT the CTIT logic utilizes N1 Speed and Compressor Inlet Temperature (CIT). For both parameters there are two sensors, the higher value of the two is used. If both CIT sensors fail a default value of 59 deg F is applied. Alarms are generated for each sensor fail. A failure of the single TOT sensor generates a shutdown. CTIT is used for all control functions. Several temperature switch outputs are generated for use by the sequencer.

The PID control operates with two different references. The start temperature reference is based on N1 Speed and biased by CIT. Figure 2-5 depicts this schedule. The setpoint switches to the run reference when N1 Speed exceeds 8400 RPM and takes control of the fuel demand. This reference is a ramp whose output can be raised and lowered by external switches. It is set at 1895 deg F initially. The setpoints for Overtemp Warning and Shutdown also change for start / run conditions.

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Figure 3-5: Start Temperature Schedule

The software in the Turbine Fuel Control has been configured for a single TOT sensor.

But the application can be changed to accommodate the use of more TOT sensors or averaging of TIT sensors is required.

3.5 Speed Governing

3.5.1 Off-Line

N1 Speed Control is established when the unit reaches the minimum speed governing setpoint during start-up. Once speed governing has been achieved and prior to circuit breaker closure (unit in isochronous mode), the RAISE and LOWER inputs from the operator are be used to control the speed setpoint within the operating range of 95% – 105% rated speed.

3.5.2 On-Line

When the generator breaker is closed, speed is still a component of control. If a unit is setting the grid frequency, the unit may remain in Isochronous (Isoch) speed control.

Otherwise the unit will be in Droop where load is controlled but may be biased by grid frequency, and therefore generator speed, deviations.

The state of the Isoch/Droop switch selection, the state of the other units, and whether the unit is tied to the utility is used to determine how the unit will operate.

a. When synchronizing to the utility, the switch is disregarded after 52G closed – unit goes into Droop.

b. When Isolated and two or more units are operating in parallel, the units follow the switch selection.

System Design Specification Page 13 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

c. When a single unit is operating Isolated, or multiple units were operating isolated and subsequently reduced to a single unit, the last unit operating will switch to Isoch, regardless of switch position.

NOTE: The Isoch/Droop switchs previously located in the packages have been moved to the control board.

3.6 KW Loadsharing

When units are operating together, load-sharing is implemented. But the operator can choose to operate an individual unit at a different load to meet emissions requirements or for other reasons.

3.6.1 Isolated Mode

When operating in Isolated mode, all units will share the load equally (balanced).

a. Load can be changed using the Coordinated control switch; which will change load proportionally to all on-line units – balanced or unbalanced.

b. Load can be increased individually to unbalance the load between units; for emissions reasons.

3.6.2 Utility Mode

When operating against the utility, the second unit to come on-line, will share load with the first unit – balanced. This is a one-time event. Load changes are done as described above.

a. The operator must use the individually speed control switches for each unit to re-balance the load, if desired.

b. If 52G opens on any of the units, re-synchronizing to the remaining on-line unit will re-trigger the load sharing event.

3.7 Combination Generator Control Module Operation

A Combination Generator Control Module (CGCM) was added to the system to replace the functionality of the old AVR and the Real Power Sensor (RPS).

3.7.1 Interfaces with Governor

The CGCM is integral to the Speed control loop for the Isochronous / Load Sharing function in this system. The CGCM senses load via the generator PT’s and CT’s. For a more detailed explanation of the CGCM’s operations refer to Rockwell Manual 1407- CGCM-DLR in Section 5 – Supplier Manuals. The purpose of this manual section is to describe how the CGCM signals interface with the Turbine Fuel control.

The CGCM generates the KW signal that is used for load control and load limiting. The CGCM also generates the Load Sharing Error signal which is used to bias the load control.

System Design Specification Page 14 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

3.7.2 AVR Functionality

The CGCM performs the automatic voltage regulator functions. The original hardwired interfaces from the Control have been left intact for the most part but the selection between Auto and Manual, also called Field Current Regulation (FC), and is made from the HMI. If in Auto Mode, then Voltage (Voltage with Droop) may be selected. Or the VAR/PF controls can be enabled. When VAR/PF mode is selected, VAR or PF control is based on the selector switch on the control board. The VAR/PF setpoint is still controlled by the potentiometer on the switchboard.

NOTE: Tracking for bumpless transfer is only done when switching from VAR or PF mode back to Voltage control; due to VAR/PF setpoint being controlled with the potentiometer.

3.8 Fuel Valve Operation

The liquid/gas fuel demands are first calculated by the following:

• Start Fuel / Acceleration Controller

• N1 Speed Governor

• kW Limiter

• TIT Limiter

These controller fuel demands are compared on a lowest wins basis, and then high selected with the deceleration fuel limiter (disabled) to provide a final control fuel demand. Before light off (TIT less than 600 degrees F) the fuel demand is held to 5% (can be changed by tuning ZSP_LITEOFFPER).

All fuel demands have been scaled for 0 to 100 percent. Each fuel valve uses an LVDT (linear variable differential transducer) provides fuel valve position feedback to determine the difference between the required and actual positions. This difference is constantly monitored and the controller will generate a shutdown if the position error should exceed ±10 degrees for more than 10 seconds (this shutdown is overridden prior to light off). Upon detection of a shutdown condition, the fuel demand output is instantly reset to zero, forcing the fuel-metering valve to fully close.

3.9 Fuel Changeover

The engine controller supports single fuel (gas or liquid) and online fuel changeover.

The user can initiate an automatic changeover from the current fuel type (which could be either gas or liquid) to the other fuel type by selecting the alternate fuel. The HMI indicates which fuel has been selected.

If the unit is not running, fuel changeover will be immediate. If the unit is running fuel changeover is allowed when the gas turbine speed is greater than 6000 rpm and there are no alarms for the LVDT or actuator driver that you are attempting to transfer to. A ramp with forward and reverse output capabilities is utilized. These outputs are used to

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Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA produce two multipliers varying from 0 to 1 that multiplies the total fuel demand. Thus, when an alternate fuel is selected and permissives are met the ramp output will start reducing the multiplier (1 to 0)) for the currently operation fuel while simultaneously increasing (0 to 1) the multiplier for the new fuel. The default rate is currently set for 20 seconds (0.05 units / second). This can be adjusted by tuning Constant input in _170_FUEL_CNTRL to SEL_74.In1. The time can be varied from 5 to 125 seconds (0.2 to 0.008). Normal operation for this site is to run on gas fuel.

3.10 Synchronization

Only manual synchronization is used. The operator can synchronize each generator with the electrical bus using the existing synchronization scopes and RAISE/LOWER switches, NOTE: The system has the capability of performing auto-synchronizing but this is not implemented currently.

3.11 KW Limiting Mode

The kW Limiter will be active whenever the generator circuit breaker is closed and there is a valid KW signal. The generator output will be limited to 3050 KW at all times.

3.12 Normal Shutdown Sequence

Normal shutdown sequencing is done by the Sequence Control (SSLL) which replicates the original Series Six. The fuel controller only has one shutdown input from the sequencer logic. Generally when a normal stop is requested, the speed setpoint is ramped down at a pre-defined ramp rate. If the unit was on-line when the stop procedure was initiated, the unit automatically unloads until the generator power output is less than 50 kW. When the circuit breaker opens, turbine cool down begins and the controller speed setpoint is reset to the synchronous speed value. Following turbine cool down (3 minutes), the speed setpoint is set to a lower value and begins a controlled deceleration. Once turbine speed is below a pre-set value, all fuel is cut-off by closing shutoff valves and issuing the shutdown command to the Turbine Fuel controller.

3.13 Unit Emergency Shutdown Operation

In the event of an emergency shutdown (e.g. ESD pushbutton, or trip condition detected), the governor will immediately close the fuel control valve and the sequence logic should command all shutoff valves to close. Any governor detected shutdown will result in de-activation of the “Governor Malfunction” relay. All shutdowns in the fuel control are of this type.

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Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

4 Control Setpoints

4.1 Control Values Summary

Table 4.1 is a summary of the control values used within the controller. The numbers in the Value column are those left at the completion of commissioning.

Table 4.1 Control Setpoints

Parameter Value Block Name Lower Limit Speed Reference

13,900 rpm Constant input in _100_N1_SPEED Sheet 2 to REF_RMP_01.LowLimit

Rated Speed Reference 14,455 rpm Constant input in _100_N1_SPEED Sheet 2 to SEL_01.In2

Raise Limit Speed Reference

15,178 rpm Constant input in _100_N1_SPEED Sheet 2 to REF_RMP_01.HighLimit

N1 Overspeed Trip 15,800 rpm Constant input in _100_N1_SPEED Sheet 1 to

CMPR_05.IN_B

Manual Speed Raise/Lower Rate

15 rpm / sec Constant input in _100_N1_SPEED Sheet 2 to REF_RMP_01.OperRate

Lower Limit Temp (TIT) Reference

1550 deg F Constant input in _140_TEMP_CNTRL Sheet 1 to REF_RMP_02.LowLimit

Raise Limit Temp (TIT) Reference

1920 deg F Constant input in _140_TEMP_CNTRL Sheet 1 to REF_RMP_02.HighLimit

Rated Temp (TIT) Reference

1895 deg F Constant input in _140_TEMP_CNTRL Sheet 1 to REF_RMP_02.InitialValue

Manual Temp Raise/Lower Rate

1 deg / sec Constant input in _140_TEMP_CNTRL Sheet 1 to REF_RMP_02.OperRate

Running Overtemp Warning

1950 deg F Constant input in _120_TEMP_MGMT to CMPR_10.IN_A

Running Overtemp Shutdown

2000 deg F Constant input in _120_TEMP_MGMT to CMPR_11.IN_A

TIT Control Setpoint During Start-Up

1100 – 1750 deg F

Schedule based on N1 Speed and CIT in _140_TEMP_CNTRL Sheet 1 to FGEN_3D_01. See START_REF_X, START_REF_Y, and START_REF_Z arrays.

Start Overtemp Warning 1570 deg F Constant input in _120_TEMP_MGMT to CMPR_08.IN_A Start Overtemp Shutdown 1600 deg F Constant input in _120_TEMP_MGMT to CMPR_09.IN_A Calculated TIT Trim 0 deg F ZSP_KTRIMR and ZSP_KTRIMS Fuel Transfer Rate 0.05 / sec Constant input in _170_FUEL_CNTRL to SEL_74.In1 KW Limiter Setpoint 3050 KW ZSP_KW_LIM_SP Light Off Fuel Percent 5 % ZSP_LITEOFFPER

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Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

5 Plant Protection Systems

5.1 Hardwired Emergency Shutdown Chain

The emergency shutdown system is used to shutoff fuel flow to the turbine by immediately closing both the fuel shutoff valves and the fuel control valves.

A hardwired, daisy chain (series) of relays should be used to supply power to the liquid and gas fuel shutoff valve solenoids. If any relay opens, power to the fuel shutoff valve solenoids will be interrupted. The most critical trip signals are wired to this daisy chain of relays to assure safe operations.

Typically, when an emergency shutdown occurs (any contact opens), both fuel shutoff valves should close immediately. There is a common shutdown signal from the sequencer to the turbine fuel controller that represents this daisy chain. The fuel control valves will be instructed to close at the maximum rate if this contact closes or a governor trip is detected.

5.2 Analog Input Fault Monitoring

Analog inputs are monitored for signal validation. If any analog signal whose normal purpose is to detect a trip, fails, then the signal failure will also cause a trip to ensure plant integrity, unless there is a redundant signal. Non-critical or redundant analog signal failures will cause an alarm only. Speed Bias and KW signal failures are overridden until the unit is determined to be “on line”. Actions for failure of valve position signals are dependent on which fuel the unit is operating on.

All alarms and trips will be displayed on the HMI. The analog input plant monitoring alarm and trip limits are defined in Table 5.2 below. Appendix A of this document contains the complete controller input/output database for further reference.

Table 5-2 Analog Signal Validation Levels Signal Signal Type Lo Limit Hi Limit Alarm Trip Speed Bias 4 – 20 mA 2 mA 22 mA Yes – Switch to

Speed Droop No

KW 4 – 20 mA 2 mA 22 mA Yes No CIT #1 4 – 20 mA 2 mA 22 mA Yes No – Switch to default value of 59 deg F if both fail

CIT #2 4 – 20 mA 2 mA 22 mA Yes See above Liquid Valve Position

4 – 20 mA 2 mA 22 mA Yes – If on gas or transferring

Yes – If running on liquid

Gas Valve Position

4 – 20 mA 2 mA 22 mA Yes – If on liquid or transferring

Yes – If running on gas

TOT TC #1 T/C 200 deg F 2250 deg F Yes Yes

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Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

5.3 Speed Fault Detection

Speed signal validation is used to detect a failure of the speed probes. Low speed signal failures are overridden until the speed exceeds 2200 RPM, TIT exceeds 600 deg F and there are no shutdowns. This is known as “Fuel On” conditions.

An emergency shutdown will occur if both speed probes fail low, or if the turbine speed exceeds 15,800 RPM as detected by the turbine fuel control or the Airpax Overspeed Switch. A contact from the Airpax is sent to the sequencer and generates both a sequencer trip and a turbine fuel control trip. Since the highest of the two speed signals are used for all control functions a failure in the high direction of only one signal will also result in an emergency shutdown.

Table 5-3: Speed Signal Validation Limits

Signal Signal Type Lo Limit Hi Limit Alarm Trip Speed #1 MPU 400 RPM 17300 RPM Yes Yes – If fails high or both fail low Speed #2 MPU 400 RPM 17300 RPM Yes Yes – Same as above

5.4 Other Alarms and Shutdowns

The controller input/output database (Appendix A, this section) lists all alarms and shutdowns. Section 5, Appendix A also lists all alarms and shutdowns and how they will be displayed on the HMI.

5.5 Control Internal System Fault Detection

The controller operations are constantly monitored to detect internal fault conditions.

Each input/output module and the microprocessor continuously conduct fault detection checks when the unit is powered. Each I/O module transmits fault and status data to the controller CPU module. Depending on the type of fault either an alarm or a shutdown will be generated. These faults are displayed as Hardware alarms, or ALMH_0xx. The alarm message on the HMI describes the specific fault. These outputs will be latched provided no reset command is given.

5.6 Alarm Acknowledge & Reset

The alarm acknowledgement button will acknowledge all alarms from all units.

Selecting a Unit’s Reset pushbutton will acknowledge and reset only the associated unit alarms. If no shutdowns are present the Governor Malfunction Relay will stay energized indicating a no trip condition.

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Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

6 Communications Each controller provides data to the redundant HMI’s via the existing Ethernet Switch.

Rockwell FactoryTalk software is incorporated into both systems providing monitoring, trending, alarming and limited (3 month or more) historization of parameters located within the new control system. Each HMI system is identical in configuration and operates independently. The HMI’s are configured for monitoring only and will not interfere with the operation of the turbine control systems (other than to acknowledge fault or even conditions). The figure below illustrates the network connections.

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Site: South Vandenberg Power Plant

Appendex A. System Alarms and Shutdowns

A.1 Hardware Faults *NOTE: The following list contained within this document is from the Factory Acceptance Test and will be completed after final site installation and commissioning.

TAG Name Description

ALMH_001 CPU NON CRITICAL FAULT

ALMH_002 PLC PROGRAMM FORCES INSTALLED

ALMH_003 PLC PROGRAM FORCES ENABLED

ALMH_004 RACK 1 SLOT 3 MODULE FAULT

ALMH_005 RACK 1 SLOT 4 MODULE FAULT

ALMH_006 RACK 1 SLOT 5 MODULE FAULT

ALMH_007 RACK 1 SLOT 6 MODULE FAULT

ALMH_008 RACK 1 SLOT 7 MODULE FAULT

ALMH_009 RACK 1 SLOT 8 MODULE FAULT (SPARE)

ALMH_010 RACK 1 SLOT 9 MODULE FAULT (SPARE)

ALMH_011 RACK 2 SLOT 0 MODULE FAULT

ALMH_012 RACK 2 SLOT 1 MODULE FAULT

ALMH_013 RACK 2 SLOT 2 MODULE FAULT

ALMH_014 RACK 2 SLOT 3 MODULE FAULT

ALMH_015 RACK 2 SLOT 4 MODULE FAULT

ALMH_016 RACK 2 SLOT 5 MODULE FAULT (SPARE)

ALMH_017 RACK 2 SLOT 6 MODULE FAULT (SPARE)

ALMH_018 RACK 3 SLOT 0 MODULE FAULT

ALMH_019 RACK 3 SLOT 1 MODULE FAULT

ALMH_020 RACK 3 SLOT 2 MODULE FAULT

ALMH_021 RACK 3 SLOT 3 MODULE FAULT

ALMH_022 RACK 3 SLOT 4 MODULE FAULT (SPARE)

ALMH_023 RACK 3 SLOT 5 MODULE FAULT (SPARE)

ALMH_024 RACK 3 SLOT 6 MODULE FAULT (SPARE)

ALMH_025 SPEED INPUT MODULE FAULT

ALMH_026

ALMH_027

ALMH_028

ALMH_029

ALMH_030 R1_S02_001_SI00 – SPEED MPU #1 (5TH STAGE) SIGNAL FAULT

ALMH_031 R1_S02_001_SI01 – SPEED MPU #2 (PTO SHAFT) SIGNAL FAULT

ALMH_032 R1_S02_001_SI02 – SPARE SIGNAL FAULT

ALMH_033 R1_S02_001_SI03 – SPARE SIGNAL FAULT

ALMH_034 R1_S02_002_VI00 – SPARE SIGNAL FAULT

System Design Specification Page 21 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

ALMH_035 R1_S02_002_VI01 – SPARE SIGNAL FAULT

ALMH_036 R1_S02_002_VI02 – SPARE SIGNAL FAULT

ALMH_037 R1_S02_002_VI03 – SPARE SIGNAL FAULT

ALMH_038 R2_S01_AI00 – TURBINE VIBRATION ANALOG INPUT SIGNAL FAULT

ALMH_039 R2_S01_AI01 – GEARBOX H.S.S. VIBRATION ANALOG INPUT SIGNAL FAULT

ALMH_040 R2_S01_AI02 – GEARBOX L.S.S. VIBRATION ANALOG INPUT SIGNAL FAULT

ALMH_041 R2_S01_AI03 – SPARE SIGNAL FAULT

ALMH_042 R2_S01_AI04 – GAS FUEL FLOW ANALOG INPUT SIGNAL FAULT

ALMH_043 R2_S01_AI05 – LIQUID FUEL FLOW ANALOG INPUT SIGNAL FAULT

ALMH_044 R2_S01_AI06 – WATER FLOW ANALOG INPUT SIGNAL FAULT

ALMH_045 R2_S01_AI07 – SPARE SIGNAL FAULT

ALMH_046 R3_S01_AI00 – CIT #1 SIGNAL FAULT

ALMH_047 R3_S01_AI01 – LIQUID VALVE POSITION SIGNAL FAULT

ALMH_048 R3_S01_AI02 – CIT #2 SIGNAL FAULT

ALMH_049 R3_S01_AI03 – GAS VALVE POSITION SIGNAL FAULT

ALMH_050 R3_S01_AI04 – SPEED BIAS SIGNAL (SYNC / LOAD SHARE) SIGNAL FAULT

ALMH_051 R3_S01_AI05 – KW SIGNAL FAULT

ALMH_052 R3_S01_AI06 – SPARE SIGNAL FAULT

ALMH_053 R3_S03_TI00 – TOT TC #1 – TYPE K SIGNAL FAULT

ALMH_054 R3_S03_TI01 – SPARE SIGNAL FAULT

ALMH_055 R3_S03_TI02 – SPARE SIGNAL FAULT

ALMH_056 R3_S03_TI03 – SPARE SIGNAL FAULT

ALMH_057 R3_S03_TI04 – SPARE SIGNAL FAULT

ALMH_058 R3_S03_TI05 – SPARE SIGNAL FAULT

ALMH_059 R3_S03_TI06 – SPARE SIGNAL FAULT

ALMH_060 R3_S03_TI07 – SPARE SIGNAL FAULT

ALMH_061 R1_S03_AO00 – WATER FLOW METER SIGNAL FAULT

ALMH_062 R1_S03_AO01 – FUEL FLOW METER SIGNAL FAULT

ALMH_063 R1_S03_AO02 – WATER METERING VALVE SIGNAL FAULT

ALMH_064 R1_S03_AO03 – VIBRATION METER SIGNAL FAULT

ALMH_065

ALMH_066

ALMH_067

ALMH_068

ALMH_069 R3_S02_AO00 – LIQUID VALVE ACTUATOR SIGNAL FAULT

ALMH_070 R3_S02_AO01 – GAS VALVE ACTUATOR SIGNAL FAULT

ALMH_071 R3_S02_AO02 – TIT METER SIGNAL FAULT

ALMH_072 R3_S02_AO03 – SPEED METER SIGNAL FAULT

ALMH_073

System Design Specification Page 22 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

A.2 Control System Alarms *NOTE: The following list contained within this document is from the Factory Acceptance Test and will be completed after final site installation and commissioning.

TAG Name Description

ALM_001 LIQ FUEL VALVE IN CALIBRATE MODE

ALM_002 GAS FUEL VALVE IN CALIBRATE MODE

ALM_003 EXCITATIION DISABLED BY SELECTION

ALM_004 BOTH CIT SENSORS FAILED (SET TO DEFAULT *59)

ALM_005 CIT #1 SENSOR FAILED

ALM_006 CIT #2 SENSOR FAILED

ALM_007

ALM_008

ALM_009 LIQUID VALVE POSITION ERROR

ALM_010 LIQUID LVDT SIGNAL FAILED

ALM_011 GAS VALVE POSITION ERROR

ALM_012 GAS LVDT SIGNAL FAILED

ALM_013 LIQUID ACTUATOR DRIVER FAULT

ALM_014 GAS ACTUATOR DRIVER FAULT

ALM_015 OVERTEMP WARNING

ALM_016 TC 1 ALARM (NOT USED)

ALM_017

ALM_018

ALM_019 N1 A SPEED SIGNAL FAILED

ALM_020 N1 B SPEED SIGNAL FAILED

ALM_021 N1 SPEED BIAS SIGNAL FAILED

ALM_022 KW SIGNAL FAILED

ALM_023 COLD JUNCTION SIGNAL FAILED (NOT USED)

ALM_024

ALM_025

ALM_026

ALM_027

ALM_028

ALM_029

ALM_030

ALM_031

ALM_032

ALM_033

ALM_034

System Design Specification Page 23 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

A.3 Turbine Shutdowns *NOTE: The following list contained within this document is from the Factory Acceptance Test and will be completed after final site installation and commissioning.

Tag Name Description

SD_001 TEMP SIGNAL FAILED

SD_002 SPARE

SD_003 SPARE

SD_004 OVERTEMP

SD_005 N1 OVERSPEED

SD_006 N1 UNDERSPEED

SD_007 LIQUID VALVE POSITION ERROR

SD_008 LIQUID VALVE LVDT SIGNAL FAILED

SD_009 GAS VALVE POSITION ERROR

SD_010 GAS VALVE LVDT SIGNAL FAILED

SD_011 LIQUID ACTUATOR FAULT

SD_012 GAS ACTUATOR FAULT

SD_013 MASTER SYSTEM FAULT – ANY MODULE FAULT

SD_014 SPARE

SD_015 SPARE

SD_016 SPARE

SD_017 SPARE

SD_018 POWER SUPPLY FAULT

SD_019 EXTERNAL SHUTDOWN CONTACT

SD_020 STAGNATION

SD_900 FIELD FLASH FAILED TO BUILD VOLTAGE

System Design Specification Page 24 of 24 ACGAL020S000002_B.doc

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

A.4 Turbine Events *NOTE: The following list contained within this document is from the Factory Acceptance Test and will be completed after final site installation and commissioning.

Tag Name Description

EVENT_001 DECEL IN CONTROL

EVENT_002 FLAME DETECTED

EVENT_003 GAS FUEL ON

EVENT_004 GAS FUEL SELECTED

EVENT_005 SWITCH TO RUN REFERENCE

EVENT_006 ISOCH SELECTED

EVENT_007 KW LIMITER IN CONTROL

EVENT_008 LIQUID FUEL ON

EVENT_009 LIQUID FUEL SELECTED

EVENT_010 RESET

EVENT_011 START FUEL LIMITER IN CONTROL

EVENT_012 LOAD SHARING ENABLED

EVENT_013 N1 SPEED > 12225 RPM

EVENT_014 N1 SPEED > 2200 RPM

EVENT_015 N1 SPEED > 8400

EVENT_016 N1 SPEED SETPOINT LOWER

EVENT_017 N1 UNDERSPEED OVERRIDE ON

EVENT_018 N1 SPEED SETPOINT RAISE

EVENT_019 RESET N1 SPEED TO RATED

EVENT_020 N1 SPEED GOVERNOR IN CONTROL

EVENT_021 TEMP SETPOINT LOWER

EVENT_022 TEMP SETPOINT RAISE

EVENT_023 RESET TEMP TO RATED

EVENT_024 TEMP > 1570 DEG F

EVENT_025 TEMP > 1600 DEG F

EVENT_026 TEMP > 1950 DEG F

EVENT_027 TEMP > 2000 DEG F

EVENT_028 TEMP > 600 DEG F

EVENT_029 TEMP GOVERNOR IN CONTROL

EVENT_030 FUEL TRANSFERRING

6 Communications