power generation americas april - · pdf filean optimal design of electrical systems ......
TRANSCRIPT
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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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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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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