PART I

505E TURBINE CONTROL

&
TURBINE INTERLOCK SYSTEM

KEBB 2X150 TPH + 1X32MW COAL BASED POWER PLANT

PT. PETROKIMIA GRESIK, EAST JAVA

PREPARED BY :
NAME : ARIPIN
HP: 081320009898
EMAIL : aripinxyz@yahoo.com
FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 1 of 14

505E TURBINE CONTROL

505E Version 2.06-6A

The 505E is 32 bit microprocessor based control to control speed ( or load) turbine and steam
extraction turbine.
Turbine Control Device : Type
Version

: 505E
: 2.06-6A

Manufacturer : WOOWARD, FORT COLLINS CO, USA.

Electrical Configuration :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Power Supply input

Signal for HP Servo valve
Signal for LP Servo valve
Analog Input point
Analog Output point
Digital Input point
Digital output point
Aux. Power
Speed Sensor input
Serial Communication Ports

: 24 VDC (18 32VDC, 77VA max, 6.25A internal fuse)

: 1 point, 4-20mA
: 1 point, 4-20mA
: 6 points, 4-20mA
: 6 points, 4-20mA
: 16 points, 18 26VDC 2.5mA.
: 8 points (NO/NC).
: 7 points, 24VDC 200mA max.
: 2 points (MPU = passive, Proximity Probe = active)
: 32 ports (Modbus communication : RS-232, RS-422, RS485)
FOR KEBB PT. PETROKIMIA GRESIK

FUNCTION OF BUTTON
1. PRGM (Program) : to change all parameter (shutdown mode)
2. RUN : to Activate the 505E
3. STOP : to deactivate the 505E (once verification is given)

PAGE : 2 of 14

4. RESET : to clear all alarm

5. F1 (Alarm) : to display any alarm
6. F2 (over speed test enable) : command for over speed test.
7. F3 : (Not Programmed)
8. F4 : to enable or disable extraction, Light ON Extraction Active.
9. SCROLL : Push the button left rigt, up down to display the parameter what do you want.
10. SELECT : push the button up or down to select current display (@)
11. ADJ : to up or down the parameter (Run Mode)
12. NO (0) : enter 0 or NO button to disable our command
13. YES (1) : enter 1 or YES button to enable our command
14. ACTR (2) : to display current actuator position (Run Mode)
15. CONT (3) : to display the parameter which is in control (Run Mode)
16. CAS (4) : (Not Programmed)
17. RMT (5) : Remote speed set point control information (Run Mode)
18. LMTR (6) : to display the valve limiter information (Run Mode)
19. Speed (7) : to display current speed & setting (Run Mode)
20. AUX (8) : (Auxiliary,Not Programmed)
21. KW (9) : to display current KW & Speed (Run Mode)
22. CLEAR : Clear Program / Run Mode entries, and takes to main display
23. EXT/ADM : Enter a decimal point or displays the extraction information (Run Mode)
24. DYN : Accesses the dynamic setting of the parameter controlling the actuator position (Run
Mode)
25. ENTER : Enter new values in the program mode. And allows the direct entry of the
setpoint values in the run mode.
FOR KEBB PT. PETROKIMIA GRESIK

26. EMERGENCY STOP : Emergency Shutdown command for the control.

PAGE : 3 of 14

FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 4 of 14

SPEED PID OPERATIONAL MODE

The Speed PID operates in one of the following modes, depending on configuration and system
conditions :
1. Speed Control ------- > Gen. And Utility Breaker are open
2. Frequency Control ---- > Gen. Breaker is Closed, and Utility Breaker is open (Single Running)
3. Unit load Control ----- > Gen. Breaker and Utility Breaker are Closed (Synchrone Running)
- Turbine HP and LP valve position control
- Generator Load Control
NOTE : in KEBB Petrokimia, signal indication for Utility Breaker is looped (jump) with
Generator Breaker.
When not programmed for Generator application, the 505E speed PID operates in a speed control
mode at all times. When programmed for Generator application, the state of the Generator and
utility breaked determine the operational mode of the speed PID.
If the Generator breaker is OPEN, the speed PID operates in a SPEED CONTROL MODE.
If the Generator breaker is CLOSED, and the utility breaker is open, the FREQUENCY CONTROL MODE
is selected.
When Generator breaker and utility breaker are close, a UNIT LOAD CONTROL MODE is selected.
While in the Speed Control Mode, the Speed PID will control a turbine at the same speed or
frequency regardless of the load its supplying ( up to the units load capability). With this
configuration, no form of droop or second controlling parameter (KW signal) is used by the PID for
stability or control.
The Unit Load PID have 2 (two) parameters to control unit load and act as a stabilizing effect for any
change in bus / utility frequency. With this configuration, when bus frequency decrease or increase,
unit load increase or decrease respectively.
F (frequency)

------- >

kW (Load)

F (frequency)

------- >

kW (Load)

FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 5 of 14

3180rpm
3210rpm

3000rpm

SPEED SETTING

50% Load

kW LOAD

FREQUENCY IS SET BY THE UTILITY GRID / PLN

LOAD VARIES WITH SPEED SET POINT

(FREQUENCY AND LOAD RELATIONSHIP)

FOR KEBB PT. PETROKIMIA GRESIK

Actual Frequency set by the utility (+/- 50Hz)

+/- 50Hz

100% Load

PAGE : 6 of 14

0%ERROR

0%ERROR

PID

PID

1. SPEED CONTROL

AND

+
-

SPEED SET POINT (UP TO 3000RPM)

TURBINE SPEED (3000RPM)

SPEED SET POINT (UP TO 3210RPM)

TURBINE SPEED (3000RPM)

GEN. BREAKER
UTILITY BREAKER

DROP CALC
5% of
Rated speed

FOR KEBB PT. PETROKIMIA GRESIK

TO
OUTPUT

TO
OUTPUT

2. TURBINE INLET VALVE POSITION CONTROL WITH FREQUENCY SWITCH ----> SINGLE RUNNING

PAGE : 7 of 14

AND

+
-

SPEED SET POINT (UP TO 3210RPM)

TURBINE SPEED (3000RPM)

GEN. BREAKER
UTILITY BREAKER

0%ERROR

0%ERROR

PID

PID

DROP CALC
5% of
Rated speed

+
-

3. GENERATOR LOAD CONTROL WITH FREQUENCY SWITCH -----> SYNCHRONE RUNNING

SPEED SET POINT (UP TO 3210RPM)

AND

5% of
Rated speed

DROP CALC

TURBINE SPEED (3000RPM)

GEN. KW

GEN. BREAKER
UTILITY BREAKER

FOR KEBB PT. PETROKIMIA GRESIK

TO
OUTPUT

TO
OUTPUT

3.
4. GENERATOR LOAD CONTROL WITH FREQUENCY SWITCH AND KW FEEDBACK -----> SYINCHRONE RUNNING

PAGE : 8 of 14

100%

0%

VALVE LIMITER

MANUAL START MODE

FOR KEBB PT. PETROKIMIA GRESIK

TIME

ACTUATOR-SERVO

3000RPM TURBINE SPEED

AND BYPASS VALVE

INLET MOTORIZED VALVE

QUICK CLOSE /HYDRAULIC VALVE FULLY OPEN

(EXAMPLE : PANASIA POWER PLANT)

PAGE : 9 of 14

100%

0%

VALVE LIMITER

FOR KEBB PT. PETROKIMIA GRESIK

TIME

ACTUATOR-SERVO

3000RPM TURBINE SPEED

INLET MOTORIZED VALVE

QUICK CLOSE /HYDRAULIC VALVE FULLY OPEN

SEMI AUTOMATIC START MODE

(EXAMPLE : KEBB PETROKIMIA POWER PLANT)

PAGE : 10 of 14

TURBINE START
The 505E has 3 (three) turbine start mode : 1. Manual Mode
2. Semi Automatic Mode
3. Automatic Mode

1. Check Turbine accessories ( example : EH Control Oil Pressure, Inlet Motorized Valve, Drain
Valve, etc) or All important parameter to allow turbine start up. if OK --- > go to 505E.
2. Start Permissive
- Open the Quick Closed Valve/ Hydraulic Valve ( Right and Left) untill fully Open, and the
limit switch will contact and send signal to 505E and DCS ----- > Fully Open
- Click the 505 Run Permission Button on the Turbine & Gen Display DCS Computer,
and click YES.
3. Push RESET button
- All alarms must be cleared, push the ALARM (F1) button to check alarm list if the button
is LIGHT ON (RED).
- If alarm still appear, check the parameter and interlock switch. The interlocked
parameter must in safe range, and the not important parameter switch while the
turbine start must be open (example : Generator Protection Switch, Vacuum protection,
extraction protection).
- 505E will ramp open the LP valve ( Extraction Valve) to fully open 100%. And the HP
valve ( Inlet Turbine Valve) still in the position fully close 0 %.
4. Push RUN button
- The 505E in RUN mode will control the Turbine speed.
- The HP Valve (Governor) will ramp open to minimum speed setting --- > 600 rpm.
- And, Set the speed according to the Turbine Star up Chart.

5. Setting The Speed

- Push the SPEED Button (7)

FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 11 of 14

Push ENTER button

Insert New Value Setting ( example : 12 00), and the push ENTER button.

ACTIVATE EXTRACTION NO. 2 IN 505E

1. Check Extraction No. 2 line ( Motorized Valve, drain Valve, etc.) to allow extraction no. 2
active / enable. If ready, go to 505E to enable the extraction no. 2.
2. Push F4, and then
3. Push YES /1 button to enable the Extraction. The display will change from disabled to
enabled, and F4 button will light on (red colour).

FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 12 of 14

SPEED VS EXTRACTION PRIORITY

Because an 505E has 2 (two) valve must be controlled ( Governor Inlet valve and Steam Extraction ).
505E can control 2 (two) parameter at a time. If the turbine reaches an operating limit, the result is
only free moving valve to control with, thus the 505E can only control 1 (one) parameter.
In KEBB Petrokimia, Speed Priority is programmed. The 505E will only control turbine speed/load
When the turbine reaches an operating limit. When programmed for speed priority, the 505E will
maintain speed/load and sacrifice extraction control. With this configuration the Extraction PID is
forced to lose control of its process.

FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 13 of 14

A. ENCLOSED DRAWING :
1.
2.
3.
4.
5.
6.

Control Oil HE Flow Chart

505E wiring Diagram for DI/DO Points
505E wiring Diagram for AI/AO Points
Turbine Hot Well Control Diagram
Turbine Alarm & Trip Setting
Turbine Shutdown Logic Diagram

B. ENCLOSED VIDEO :
1. 505E Button Fuction
2. 505E RUN and Speed Setting
3. 505E Extraction Activation / Deactivation
4. 505E Service Mode

FOR KEBB PT. PETROKIMIA GRESIK

PAGE : 14 of 14

LAMPIRAN : 1 of 6

FOR KEBB PT. PETROKIMIA GRESIK

LAMPIRAN : 2 of 6

FOR KEBB PT. PETROKIMIA GRESIK

LAMPIRAN : 3 of 6

FOR KEBB PT. PETROKIMIA GRESIK

LAMPIRAN : 4 of 6

FOR KEBB PT. PETROKIMIA GRESIK

LAMPIRAN : 5 of 6

550 mm or 850 mm
150 mm or 450 mm
35% <290mm

0.79MPa

20% <210mm

0.89MPa or 1.49 MPa

-0.45MPa

8.3MPa or 9.0 MPa

-0.65 MPa

0.08MPa

95C

95C

95C

110C

110C

110C

110C

9.6MPa

0.3MPa

0.13MPa, DC oil start

0.65MPa, HP pump Start

10.5MPa

3210rpm

95C

110C

510C or 540C

95C

70C

70C

100C

100C

100C

80C

70C

80m

-0.8mm or 0.08mm

120m

60C

-0.6mm or 0.6mm

Spdt

> 14.0Mpa -----> pump A STOP

FOR KEBB PT. PETROKIMIA GRESIK

< 10.5Mpa -----> pump A START

jika pressure masih rendah dari :

< 10.0MPa -----> pump B START ( 2 motor A & B START)

120m

120m