power generation americas april - · the abb integration ... unitrol emax msd acs 800 hmi and...

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Power GenerationAmericas

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7Power Generation Business Mandate

� Deliver automation & electrification solutions to Power Generation clients in the power & process industries

� Includes the turnkey supply of “ICE” (Instrumentation, Control, and Electrical) solutions

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Integrated Electrical and Control Solutions

Control room

Control Systems

Step UpTransformer

HV System

Star Point Cubicle

HV Substation

Static Starter

Synchronization

1

Excitation Transformer

Power Island

TURBINE

AuxiliaryTransformer

IPBTurbine Governor

1

Unit Protection

MV/LV-Switchgear & Drives

Generator-Circuit Breaker

GExcitationSystem

CIVIL WORK

Mechanical BoP

HRSG

BOILER

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12Condition Monitoring

Solutions for all Rotating Machinery

Utility Steam TurbinesAuxiliary Steam Turbines

Combustion Turbines

Industrial Steam Turbines

Hydraulic Systems

Turbine Automation

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7Power Generation – ICE Integration Experts

The ABB Integration Experts Creating an environment of optimized and efficient operations by combining innovative products, power generation specific solutions and the latest IT technology through the industry’s most experience engineering staff

Plant Optimization Systemsincluding, plant management and

asset management solutions specifically designed for Power

Generation

Plant Automation SystemsField Devices,

Instrumentation& Distributed

Control Systems

Plant Electrical SystemsElectrical Equipment /

Products used in Balance of Plant

applications

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� Thermal Power Plants

� Combined Cycle/Cogeneration

� Hydroelectric Power Plants

� Institutional Steam Plants

� Water/Wastewater Plants

� Training Simulators

� New and Retrofit Projects

Plant Experience

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7Optimizing global reach with regional synergy

USA

India

Regions

GermanyChina

Italy

Brazil

Regional hub

Sweden

UAE

NorthAsia

SouthAsiaMiddle East

and Africa

Southern EuropeNorth

America

South America

Central Europe

Northern Europe

Eight regions with “borderless” ABB teams

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Basic Design•Feasibility studies•Redesign & calculation

Engineering ProcurementAssemblyTesting

Erection /Commissioning•Dismantling of existing equipment

•New installation

Service

Scope of Services

Project Management

Your Life Cycle Partner

Project-development

Retrofit

Rehabilitation

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7Your Partner for Service and Maintenance

Training

SparesService Contracts Expert Consultancy

Remote service, Maintenance system

Trouble shooting

Modernization, Expansion

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Maximizing value for our customers

� Risk management� Lower project cycle costs� Integrated technology

� Greater operability� Lower training costs� Ease of life cycle maintenance

Electrical systems Instrumentation /Control

ABB Composite Plant Solutions

AutomationSolutions

MV / LV

PowerDist.

Trans-forme

rs

GCB and IPB

Motors and

Drives

Excit. and

Synchr.

Optimiz. SafetySystems

Intelli-gentFieldInstr.

AnalyzersValves

andActuat

System Integration

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7Rehabilitation / Optimization

� Consulting and studies

� Plant optimization

� Life-cycle support and solution

� Implementation of modern technologies

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7Composite System Solution

DCS-Configuration Single Line Diagram

Process knowledge is a prerequisite for an optimal design of electrical systems

� Mode of operation� Component design� Sizing and layout

HV, MV, LV, transformers� Duty cycle� Start up / shut down� Plant maneuverability� Load flow, voltage drop

Objectives� Availability

� Redundancy

� Performance

� Standardization

P&IP&I

Optimized Interface

Managenment

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7Composite System Solution

DP/V1

REF 542+ Protection,ControlREG/T Synchrotact 5 UMC

IEC 60870-5-101/-104

Controller

CACCBC

S800 I/O

Local I/O

Intelligent Field Devices & Drives

System 800xA Server

Unit Protection- Generator

Protection

- Synchronization

Electrical System Low Voltage

(LV)

Electr. System Medium Voltage

(MV)

Consumers Low Voltage (LV)Consumers Medium Voltage

(MV)

- Unidirectional DrivesFrequency converter

ACS 1000TmaxEmax MSD ACS 800Unitrol

HMI andInformation Management

IndustrialIT System 800xA

RTU

- Actuators- Unidirectional Drives- Frequency converter- Intelligent Drives- Magnetic valves

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•• Complete Turbine ControlComplete Turbine Control

•• Interface with Supervisory ControlInterface with Supervisory Control

•• Combustion TurbinesCombustion Turbines (1~250MW)(1~250MW)•• E, F and G TechnologyE, F and G Technology

•• Steam Turbines (7MW~600MW)Steam Turbines (7MW~600MW)•• Extraction and NonExtraction and Non--extractionextraction

•• Single / Separate ShaftSingle / Separate Shaft

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Application Knowledge

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•• Heat Recovery Steam GeneratorsHeat Recovery Steam Generators•• Single, Dual, Triple PressureSingle, Dual, Triple Pressure

•• ReRe--heat / Non Reheat / Non Re--heatheat

•• Natural / Forced CirculationNatural / Forced Circulation

•• Fired (BMS) / NonFired (BMS) / Non--firedfired

•• Once ThroughOnce Through

•• Diverter Damper Diverter Damper

•• Bypass System Bypass System -- Common or Per H.R.S.G. Common or Per H.R.S.G.

•• Main Steam ExtractionMain Steam Extraction

•• Auxiliary Steam HeadersAuxiliary Steam Headers

•• Single / Multiple GridsSingle / Multiple Grids

•• Condensers Condensers -- Conventional or AirConventional or Air--CooledCooled

•• Cooling TowerCooling Tower

•• Electrical SwitchyardElectrical Switchyard

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Application Knowledge

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Total Cost Reduction� by elimination of redundant activities/coordination by

suppliers and customer� by reduction of risk exposure: Schedule, Extras

- Project management- Administration- Specification- Evaluation- Procurement- Engineering- Interfaces

Value of partnership with ABB

Multiple Manufacturers

ManufacturerScope 1

ManufacturerScope 2

Manufacturer Scope n

Customer's Efforts

Customer´sRisk

Exposure

ABB as your partner

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7Genesee III (Alberta)

� Hitachi & EPCOR

� New 495 MW Supercritical Pressure Coal Fired Unit

� First SC unit in Canada

� Distributed Control System

� Automated Control & Operation

� Simulator for Operator Training and Design Verification

� Very large installed base in automation systems

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7Mid American (USA)

� Iowa – Council Bluffs G4

� New 780 MW Supercritical Unit by Hitachi

� Scope includes controls

� BMS, BOP, Modulating, FGD, DAS, Mark UI Interface, MCC I/F,

Combustion Optimization, HVAC

� I/O count >13,000, HMI Tag Count > 40,000

� PLC Network => Integration of 17plc’s Modicon/WW (11 different

suppliers) into one integrated network system with connections to DCS

� Training Simulator (bid to MEC directly)

� Plant Communication System (bidding)

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Reference Vassilikos, Unit 3

Plant� Place: Vassilikos/Cyprus; 120MW oil-fired

� Completion: June 2005

Customer� Alstom Power (Germany)

Scope� Main DCS, Turbine Control,

Electrical Systems

Electrical Systems� Generator Busduct and Breaker� MV-switchgear 25 panels� LV switchgear 53 panels� AC/DC-Converter 4 pcs� UPS 2 converters� Batteries 220V, 110V� High Speed Transfer Device 1 panel� Unit Protection REG 216 3 panels

� Synchronization SYCHROTACT 1 panel� Metering 1 panel� LV Cabling 15.100 m� MV Cabling 4.800 m� Outdoor-/indoor earthing 5.500 m

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Reference Rothensee 3&4

Plant� Waste-to-Energy Plant (40 MW)� Place: Rothensee/Germany� Completion: 11.2005

Customer� ALSTOM Power Conversion GmbH

Scope� Instrumentation, DCS, Electrical Systems

Electrical Systems� 30 KV grid connection to substation� Main transformer 45 MVA 1 pc� GCB and cable connection to main

transformer� MV/LV-transformers 2/4 pcs� MV/LV-switchgear 10/14 panels� Frequency converters 9 pcs� AC/DC-converter (220V DC) 2 pcs� Batteries 220V/1200Ah 2 pcs

� UPS (230V)� DC/DC-converter (24V)� Emergency Diesel 1600 kVA 1 pc� Metering 1 panel� MV/LV-Cabling� Outdoor-/indoor earthing,lightning protection� Lighting and power installation

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7Value: Complete water to wire packages

� Best in class suppliers� High quality, proven solutions� Complete range of expertise from hydrology to remote dispatch� Optimum solutions for each situation

� Maximize the use of the water resource � Optimum mechanical design – guaranteed capacity and efficiency� Optimize operations – reliability, automation, joint control, remote

dispatch, deregulated markets,

� Global approach� Project experience in almost every country of the globe� Global sourcing and project management – optimum solution for

each country, situation� Financing options

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7Hydro Applications

� Full automation, remote control

� Dispatch, area management

� Hydrological solutions

� Joint Control & Optimization

� Cascade Control

� Pumped Storage

� Deregulated Markets� Hydro scheduling, Hydro-thermal

coordination

� Predictive production costing

� Planning, scheduling, billing

� Operations planning

� Turbine Governors

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7Yixing Pumped Storage (China)

� GE/ABB Consortium for

Electromechanical Package

� 4 x 250 MW Pumped Storage

Hydro Power Plant

� Fully Integrated Control &

Protection Systems

� Completely Automated – remote

control from two dispatch centers

� Electrical Scope: MV

Switchgear, Generator Circuit

Breaker, Isolated Phase Bus,

Excitation, SFC, Cabling

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Yixing – Large Screen

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7Cheongsong - Korea

� 2x306MW Pump Storage

� GE-ABB consortium

� Control, Protection, SFC, Excitation

� Remote control Samrangjin

One Line Control

Protection Prot System

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7Cheongsong 600MW Pumped Storage Korea

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7Cheongsong – Control Room

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7Cheongsong 600MW Pumped Storage Korea

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7El Canada (Guatemala)

� Project: 2 x 26 MW Units

� Executed in consortium with GE Hydro (Norway)

� Complete Turnkey “Water to Wire”Responsibility

� Substation (ABB Spain)

� ABB Scope:� Control

� Protection

� Station Service

� Main Transformer

� Engineering & Commissioning

� Installation

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7Rio General (Costa Rica)

� GE/ABB Consortium

� Project: 2 X 26 MW Unit

� ABB Scope:� Control (local/remote

interface)� Protection� EBoP� Substation, Transmission

Lines (NOABB)� Engineering, Training,

Commissioning

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7Porce III H.P.

� Colombia, South America

� Toshiba/ABB Consortium for EM package. Partnership with Mitsui & Co. Ltd.

� New Hydro project, 4 X 165 MW.

� Contract signed Nov. /2006

� Commissioning scheduled end of 2009

� ABB Scope (11 MUSD)� Generator Circuit Breakers� Isolated Phase Busbar System� Excitation System + AVR� Local Control Cabinets� Generator Instrumentation� Vibration Monitoring System

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7ABB/Mavel: Concepcion (Panama)

� ABB/Mavel Consortium� Project: 2 X 5 MW � 2 Horizontal Francis

Turbines� Based on model test� Water to Wire package,

including bifurcation� EPC Contractor – work

closely together� Capacity and efficiency

guarantees� First project of its kind in

Panama

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7Nam Theun II (Laos)

� GE/ABB/Clemessy Consortium for EM package

� Hydro: 1180 MW (4x270, 2x50)

� Bid submitted July 2002

� Selected vendor & contract signing in Dec. 2004

� Financial closure -> May 2005

� Completed in 2009

� ABB Scope (60 MUSD):� Control & Protection

� Excitation

� Telecommunications

� Main Unit Transformers

� 500/115 kV Substations

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Dam

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Spillway/Dam Controls

Substation Protection & Control

TelecommunicationsSecurity/Access Systems

Plant Automation

EHV Substation

Protection

Excitation

Unit Controls Governor

Gen..C.BrakerStep-up Transformer

Field Instrumentation

Turbine

GeneratorBus-duct Electrical -

LV+MVAuxiliaries

Mechanical Auxiliaries

TransmitionSystem

Pen-Stock

Hydroelectric Power Plant Upgrade: More Power

Runner Replacement

Generator Rewind

Excitation Upgrade

Automation Upgrade

GCB Upgrade

Main Transformer Upgrade

Substation upgrade

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7Kemano Project Scope 8x125MW

� Full service solution: from site study to long term maintenance

� Complete automation including mechanical upgrades

� Joint control and performance optimization of 8 units

� Performance optimization – Surge shaft level control

� Complete remote control from Kitimat including Power Line Carrier between Kemano and Kittimat using existing power line

� Turn-key: Installation and commissioning

� Risk-Reward type contract

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7Kemano Project Scope 8x125MW - Electrical

� 300kV XLPE Insulated cable upgrade by 4x3 phase circuits – 1km

� 13.8kV/300kV 130MVA Transformers including transformer protection

� 13.8kV HEC-5 GCB with protection

� 13.8kV/24kV Station Service transformer and switchgear protection

� Unitrol-5000 Static Excitation System

� 300kV Surge Arrestors at both the Kemano and Kittimatsites

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7Kemano Automation System

Operations Network TCP/IP

ONETONET

Operations Network TCP/IP

Kitimat MIS LAN

Control Network

Control Network

RemoteController

ControlTieline

RemoteController

UNIT 1LCU

UNIT 8LCU

StationCommon

LCU

Kitimat Central Control Room

Total: 8 Units

(85 KM)

Kemano Hydro Power Plant

Satellite UplinkCanComm

LeasedServices

BC TelDedicated

Fractional T1

300 KVTransmission Lines

Line 1

Line 2

Power Line CarrierSystems

Bailey Bailey Bailey BaileyBailey

Landis&

GYRSCADA

LinkSwitchyard

LCU

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7EDELCA Guri (Venezuela)

� Venezuela, South America

� Hydro Automation System

� 10 GW (20 units, 2 Powerhouses)

� Hydro Plant Automation Upgrades

� ABB Scope

� Unit Control System (20 units)

� Generator Protections (7 Units)

� Instrumentation (1500 IED’s)

� Communications

� VIMOS, CCTV,

� Consortium VEABB – CAABB -CHABB

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7Network Management - Hydro ProjectHydro Project

••Client Base:Client Base:- 43,000 customers

- 5000 sq. miles service area

••Communications:Communications:- 75 baud power line carrier

- leased line- microwave- fiber optic- DNP 3.0

••Interface:Interface:- Decision Support System (DSS)

••Remote access:Remote access:-Sault Ste. Marie

- Burlington- Houston

••Operation:Operation:-12 hydroelectric generating stations

on four river systems- 22 generating units

total capacity of 302MW

Great Lakes Power Limited

••Data Base:Data Base:- 3000 Points- 200 busses- 24 RTUs

••Transmission:Transmission:- Distribution through four

substations- 443 miles of transmission lines

- 3 OHSC interconnections- 1 LSP 110MW Cogen. connection

- SCADA- Energy Management System- Dispatcher Training Simulator- Distribution Substation Control- G.S. Auto Sync & Load Control

- Automatic Generation Control- Neural Network Load Control- Islanded G.S. Control Capability- Hydro Coordination - Historian

••Applications:Applications:

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7EPM Guadalupe (Colombia)

� Colombia, South America

� Hydro Chain Control/Optimization

� 528 MW (3 plants)

� Hydro Plant Automation Upgrades

� ABB Scope

� Hydro Chain Control and Optimization

� Plant Control (local/remote)

� Station Service (AC/DC distribution)

� Instrumentation (COABB)

� Engineering, Training

� Commissioning Supervision (COABB)

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UI060-02A

Contact, New Zealand, Scope and Features

� Turn-key responsibility� Complete control system upgrade

� System design and manufacturing

� Site engineering

� Installation and commissioning

� Integrated governor (12 units)

� Combined joint control for the two plants

� Remote control of Roxburgh

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Contact – Roxburgh and Clyde

OWS (3-screen)

Architecture OverviewClyde & Roxburgh Hydroelectric ProjectABB Proposal 4720 9135_0

OWS

Firewall/Router

Unit Control(4 required)

TransformerRIO

StationServices

SpillwayGate PLC

Sluice GatePLC

Control CentreComputer hardware by Contact

Firewall/Router

Servers

S D

Ci sco 17 20

BRIS/ T

CONSO LE

AUXWI C 0 O K

OK

B2

B1

WI C 1 O K

DSUCPU

LNK100FDX

S3

LO OP

LP

CoolingWater / OilSystem RIO

RTD RIO

DrainagePump RIO

Draft TubeRIO 2

Draft TubeRIO 1

EWS

CLYDE

B&W Colour

Clutha Control Centre

Colour

Duty Asset Room

Servers

Control Room

EWS

Colour

Duty Asset Room

REMOTE CONTACT SITEROXBURGH

AirCompressorRIO

Server Room

Gateway (toPI, GMS metering)

Server Room

Unit Governor(4 required)

Existing

Hawea Gate Unit Control(8 required)

RTD RIO(x2)

StationServices

SpillwayGates RIO

Sluice GateRIO

AGC

SwitchyardRIO

HeadgateRIO

MachineFloor RIO

MachineFloor RIO

Sump RIO

Intake RIO

By Others

GPS timereceiver

DAT

Diesel GenRIO

415 VACRIO

Penstock &Draft Tube

RIO

Unit HMI(4 required)

Station ServicesHMI

Unit HMI(8 required)

Station ServicesHMI

Gateway(to DMT)

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7Value of ABB Composite Solution

Lowers Total Project Cost� Minimal coordination for ABB scope� ABB coordinates with main equipment suppliers� Reduced installation costs� Reduced commercial risk (Schedule, Interfaces,

Responsibilities)� SAT/Startup costs are significantly reduced as

EPC personnel are not required Added Value to Client� Increased quality, availability and reliability� Optimized design� Reduced operating costs

Supports Fast Track Projects� Guarantee for delivery dates/Schedule Protection� No risk in integration and coordination� Access to comprehensive product range

Reducing Customer’s Resources� Using ABB’s extensive project experience� Interfacing with only one partner� Reduced technical risk

power generation americas april - · the abb integration ... unitrol emax msd acs 800 hmi and...

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