Control Systems. Power Generation and Distribution AUTOMATION. Hydro. Thermal. Gas/Diesel

Transcription

1 AUTOMATION Hydro Thermal Al Qaim (Iraq) Al Shemal (Iraq) Jorf Lasfar (Morocco) Petkim (Turkey) Aswan High Dam (Egypt) Kidatu (Tanzania) Kihansi (Tanzania) Three Gorges (China) NEK (Bulgaria) Ertan (China) Karun (Iran) Yali (Vietnam) Manantali (Mali) Gas/Diesel Nouadhibou (Mauritania) EDD Boulaos (Djibouti) Omar (Syria) Control Systems

2 Aswan High Dam - Egypt AHD power plant generates 2100 MW. Main functional units are: 12 generating units - each consisting of turbine (Frances type, max. gross head 74 m) generator (60 pole, 100 rpm, 180 MW max, kv) unit transformer (500 kv) 2 switchyards: 500 kv (2 exit lines) 132 kv (4 exit lines and 2 feeders) 2 auto-transformers: reducing the voltage from 500 kv to 132 kv and 6 kv controller's cabinets design, specification and manuf. supervision DCS design documentation and site survey process controllers application design, programming and testing operator stations application design and customizing factory acceptance test with client wiring supervision, I/O check, synchronization, transducers adjusting and installation, unit & switchyard circuit breakers synchronization commissioning and start-up training for operation and maintenance personnel Entire power plant is controlled by ABB DCS - process controllers and runs fully automatic. Control includes: turbines, generators, breakers, transformers, subsystems etc. Number of wired I/O signals: Configuration Process controllers - AdvantController 450 (17 units) Operator stations - AdvantStation 500 OS (3 units) Operator stations - Windows NT based PC application (2 units) Information Management Station - PC based application (2 units) Local Viewers - PC based application (26 units) Event/alarm printers, hardcopy printers and report printers. 17 January 2001 September 2001, 6 INTEA s engineers worked in Alstom, Denver-USA, on project design, cubicle production supervision and factory acceptance tests. October 2001 November 2003, 6 INTEA s engineers worked on site (in shifts) until successful handover , DCS HW and SW deliveries: extensions, modifications, site activities and commissioning due to Voith- Siemens scheduled overhauls of generating units. INTEA s work was recognized, by ALSTOM project management and end-user HPGC, as outstanding and highly professional.

3 Kidatu - Tanzania Kidatu Dam is Tanzania's largest Hydro Power Plant. Total generating capacity: 200 MW No. of units: 4 HD About the Project Partial upgrade/migration of existing Simatic S5 control system to S7 was selected by the end user as optimal, cost-effective solution. It included upgrade of processors, communication modules and SCADA, without replacement of the I/O modules. INTEA Delivery Engineering services project management design engineering application engineering factory acceptance tests onsite training site works Hardware & Software Delivery Process controllers, operator panels, eng. workstation, Step7 and WinCC, Equipment for communication between process controllers and SCADA, Industrial time synchronization central plant clock with GPS radio clock, SCADA system software license, Commissioning spare parts. The system controls and monitors: 4 generating units, Auxiliary PS, Auxiliary building, Switchyard, Dam, Overall Station functions. Control system is based on 9 Siemens SIMATIC process controllers (Unit1, Unit2, Unit3, Unit4, Aux PS, Aux Building, Switchyard, Dam and Station Controller) and IGSS 32 SCADA running on standard PCs with MS Windows. 4 Outcome With minimal upgrade costs and plant downtime, the control system is now based on up-to-date HW & SW, completely in accordance with recognized, international standards. The upgrade has increased reliability and availability of the plant and improved its operation and performance. End user's satisfaction was confirmed by awarding further contracts related to similar overhauls of their other powerplants.

4 Kihansi - Tanzania Total generating capacity: 180 MW No. of units: 3 (Pelton turbines) Facility has been in operation since December Concrete gravity dam on the Kihansi River has a height of 25m and a length of 200m, which creates a reservoir with a storage volume of 1 million m³. The turbines use the 900m drop in the Kihansi Gorge over a distance of about 3km, and return the water to the river about 6km downstream. control system hardware (ABB IndustrialIT: 8 x AC 800M controller, 2 x 800xA operator's workplace + 1 x 800xA engineering workplace; 3 servers, printers, GPS clock) system software & licenses engineering works (Project management, Application engineering, F.A.T.) technical training site works (pre-commissioning and commissioning of process controllers, start-up of operator and engineering workplaces, testing of the complete DCS, site acceptance test) Control system (CS) provides integrated control and monitoring of the overall plant operation from central control room. It is based on ABB 800xA Extended Automation and AC800M process controllers. CS controls and monitors: three generating units G1-G3 (unit controllers), auxiliaries and common devices (common controller), station control (station controller), 33kV and 220kV switchyard (switchyard controllers), Intake and dam RTU (intake RTU). Outcome With minimal upgrade costs and plant downtime, the control system is now based on up-to-date HW & SW. The upgrade has increased reliability and availability of the plant as well as improved its operation and performance. At the same time, maintenance costs are significantly decreased. Client's satisfaction was confirmed in a formal, written record.

5 Three Gorges - China The Three Gorges Hydropower Station is comprised of two power plants, situated on each side of the central spillway, with a total of 26 generating units. Each generating unit has a capacity of 700 MW, the size of a baseload powerplant. The total capacity will be MW, with a planned annual power generation of 84.7 billion kilowatt-hours. When completed, it will be the single greatest power plant in the world. DCS design documentation - specifications for Information Management System process controllers - "Transit node" application design, programming and testing training for operation and maintenance personnel site support - technical expertise Information Management System specification Design and development of "Transit node" - ABB AdvantController 450 application to support and manage data communication Documentation and technical training for end-user's personnel Site intervention - technical support

6 NEK - Bulgaria s NEK system project covers 3 hydro power plants: Belmeken (375MW), Momina Klisura (120MW) and Sestrimo (240MW). Distributed control system - SW design specification and other documentation process controllers application design, programming and testing operator stations application design and customizing SW lead engineering and coordination Power plants are controlled by ABB DCS - process controllers and run fully automatic. Control includes: turbines, generators, breakers, transformers, subsystems etc. Number of wired I/O signals: Configuration Process controllers - AdvantController 450 (12 units) Operator stations - AdvantStation 500 OS (6 units) Information Management Stations - AS500 IMS (3 units) Control network MasterBus 300 and Plant network TCP/IP Event/alarm printers, hardcopy printers and report printers DCS SW - project leading INTEA s work was recognized, by ABB project management as outstanding and highly professional.

7 Ertan - China The plant is located near Panzhihua on the Yalong river (a tributary of the Yangtze) in Sichuan province. Total installed plant capacity is 3300MW (6x550MW). Construction began in Ertan power plant produced 3.9 billion kilowatt hours of power in the first year of operation since August 1998, when its first generating unit went into operation. Completed at the end of 1999, it has set a new record for speed of installation of a hydroelectric project. INTEA took part in: process controllers application design, programming and testing operator stations application design and customizing communication troubleshooting intervention control system upgrade, extension and modifications Power plants are controlled by ABB DCS - process controllers and run fully automatic. Control includes: turbines, generators, breakers, transformers, subsystems etc. Configuration Process controllers - AdvantController 450 (12 units) Process controllers - AdvantController 110 (2 units) Process controllers - AdvantController 410 (3 units) Operator stations - AdvantStation 500 OS (5 units) Information Management Stations - AS500 IMS (3 units) Control network MasterBus 300 and Plant network TCP/IP Event/alarm printers, hardcopy printers and report printers F.A.T. with the client Application development Intervention, communication problems analysis Control system upgrade Control system upgrade Site interventions and technical support System extensions, interventions and technical support

8 Karun I - Iran Location: Karun river, Iran Operator: Khuzestan Regional Electric Power Configuration: 8 X 250 MW Francis Operation: since INTEA took part in: process controllers application design, programming and testing F.A.T. with the client technical training for client's operation and maintenance personnel Power plant is controlled by ABB DCS - process controllers and runs fully automatic. Control includes: turbines, generators, breakers, transformers, subsystems etc. Number of wired I/O signals: Configuration Process controllers - AdvantController 450 (9 units) Process controllers - AdvantController 110 (7 units) Operator stations - UNIX based PC (5 units) Control network MasterBus 300 and Plant network TCP/IP Event/alarm printers, hardcopy printers and report printers Application development F.A.T., technical training for the client, commissioning

9 Yali - Vietnam Yali Falls Dam was the first of the proposed dams in the Se San River basin to be constructed. Construction of the dam commenced in 1993, and was completed in December The 69 meter-high dam was sealed in The 64.5 km2 reservoir was filled by Yali HPP is composed of 4 units totaling 720 MW and highvoltage 500kV switchyard (6 lines). DCS site survey process controllers application design, programming and testing operator stations application design and customizing factory acceptance test with client DCS commissioning training for operation and maintenance personnel Entire power plant is controlled by ABB DCS - process controllers and runs fully automatic. Supervision and control includes turbines, generators, breakers, transformers, subsystems, e.g.: 4 units high-voltage switchyard water intake gates spillway structure auxiliaries and station service Number of wired I/O signals: Configuration Process controllers - AdvantController 450 (6 units) Process controllers - AdvantController 110 (5 units) Operator stations - AdvantStation 500 OS (2 units) Control network MasterBus 300, Plant Network TCP/IP Event/alarm printers, hardcopy printers and report printers technical trainig for clients personnel site survey DCS commissioning

10 MANANTALI - Mali Manantali consists of the Manantali dam on the Bafing river, a power station and a network of transmission lines. The dam is 1460m long and 65m high. It created a reservoir with a storage capacity 11,3 million m 3 and a surface of 477km MW hydro power plant consists of: 5 units - 40MW each and 2 switchyards - 225kV and 90kV. Three 225kV lines run to Bamako (Mali capital, 322km), Dakar (Senegal, 820km) and Nouakchott (Mauritania capital) (226km). One 90kV line connects Manantali HPP and a town of Kaedi (Mali, 87km). process controllers application design, programming and testing operator stations application design and customizing factory acceptance test with client Entire power plant is controlled by ABB DCS - process controllers and runs fully automatic. Supervision and control includes turbines, generators, breakers, transformers, subsystems, e.g.: 5 unit groups 2 high-voltage switchyards water intake gates auxiliaries Number of wired I/O signals: Configuration Process controllers - AdvantController 410 (8 units) Process controllers - AdvantController 70 (5 units) Operator stations - AdvantStation 500 OS (3 units) Control network MasterBus 300, Plant Network TCP/IP Event/alarm printers, hardcopy printers and report printers. May 2000 August 2000, process controller and operator station - application design, programming and FAT with the client.

11 Power Generation - Circulating Water System Al Qaim - Iraq Thermal Power Plants Chemical complex "State Company for Phosphate" - Al Qaim, Iraq - consists of integrated and interrelated plants to produce different kinds of phosphate fertilizers as a final product. Local power plant 2x14 MW is based on two steam turbine generating units TG1 and TG2. INTEA has delivered complete control system, including: design engineering, application engineering, HW manufacturing and assembling, factory acceptance test with the client, site works and commissioning, end user technical training. Main parts of Al Qaim SCP steam turbines control system are: Process controllers - ABB AdvantController 160 (4 units), Operator stations - ABB IndustrialIT 800xA (2 units), Engineering station - ABB 800xA Engineering Workplace (1 unit), Communication networks, printers and uninterruptible power supplying units. INTEA is present on Al Qaim SCP plant since Even before the project start, INTEA was engaged in site survey and finding optimal solutions for steam turbines control system modernization.

12 Power Generation - Circulating Water System Al Shemal - Iraq Thermal Power Plants Al Shemal TPS is a new 1400 MW thermal power plant consisting of 4 units (4x350MW). Circulating water system (CWS) Primary task of the CWS is to provide cooling water from Tigris river for main condenser and closed cycle cooling water heat exchangers. The circulating water intake structure also provides river water for screen wash system, service water system, fire fighting system and raw water treatment plant. The circulating water intake structure and pump station are sized for four 350 MW units with possibility of extension with two similar units. Main CWS parts water intake accessories circulating water pumps lubrication water pumps swing check valves design documentation process controllers - application design and development operator stations - application design and development control cubicles and other equipment delivery system integration F.A.T. - testing with the client training for operation and maintenance personnel "As manufactured" - documetation delivery Main CWS parts listed above are supervised and controlled by process control software applications running in 8 ABB process controllers AdvantController 800M and auxilliary electrical equipment mounted in 8 control cubicles. Number of wired I/O signals: DCS Configuration Process controllers - AdvantController 800M (8 units) Operator interface - Process Panel 245 (2 units) Control network and Plant Network TCP/IP Control system design, final design project documentation Distributed process control and supervision system, integration, programming, testing and equipment delivery.

13 Power Generation - Process Utilities Thermal Power Plants Jorf Lasfar - Morocco Jorf Lasfar power plant consists of 4x330 MW coal-fired/steambased turbo-generators. With total production capacity of 1320MW this is the largest independent power plant in Africa. Process utilities - control and supervision system: process controllers application design, programming and testing operator stations application design and customizing commissioning ABB DCS Configuration Process controllers - AdvantController 450 Process controllers - AdvantController 160 Operator stations - AdvantStation 500 OS Control network MasterBus 300, Plant Network TCP/IP application design, programming and commissioning coal handling intervention, program modifications, system maintenance program modifications & commissioning

14 Gas and/or Diesel Power Plants Nouadhibou - Mauritania Diesel power plant Nouadhibou configuration: 4 x 5,5 MW; 12PC2.5V400D engines, 500 rpm, 2 x 11 MW, 600 rpm; Voltage: 15 kv/50 Hz INTEA scope of supply for the project was: ABB 800xA distributed control system (DCS) equipment, ABB DCS system software, DCS application software, DCS engineering and site works, end user DCS technical training. DCS controls and monitors: two new diesel generators G5 & G6, 15kV switchyard - protection relays, common systems and equipment. DCS Configuration Main ABB equipment comprises: Process controller - AC800M with remote I/O & local panel, Operator/Engineering stations 800xA (5 servers + 3 clients), Control network - ModuleBus, TCP/IP plant network, Separate network segments for G5&G6 and 15kV switchyard, MODBUS communication with panel instruments, GPS clock, UPS, printers, large display; Control System Upgrade Delivery of additional HW Control System Extension Delivery of additional HW Delivery of additional HW

15 Gas and/or Diesel Power Plants Centrale de Boulaos - Djibouti BOULAOS power plant operates in Djibouti grid with 100 MW of total power. Main parts of the system are: 13 generators (6 more in Marabout), 63 and 20kV overhead lines (246 km), 279 transformer locations INTEA scope of supply related to the ABB DCS since 1999 was: design engineering, ABB 800xA and other equipment delivery, system software delivery, application software, engineering and site works, end user technical training. Power generation is controlled by process controllers. Control includes: turbines, generators, transformers, subsystems etc. DCS Configuration Presently, automation subsystems originate from various manufacturers, mostly ABB and Siemens. Main ABB equipment comprizes: Process controllers - AdvantController 110 (4 units), Process controllers - AdvantController 160 (4 units), Process controllers - AC800M (2 units) Operator stations 800xA (8 servers + 5 clients), Control network - Advant Fieldbus 100, TCP/IP plant network. 16 Most significant DPP Boulaos projects: Commissioning and system optimizing DCS visualization system upgrade Integration of G22 in the DCS xA extension and training DCS extension - G24 alarms Upgrade of 4 x ABB AC110 to 4 x ABB AC160

16 Gas and/or Diesel Power Plants OMAR - Syria OMAR power system network operates in island mode, covering area of some 100km2, with 200MW of total power. Main parts are: 18 distributed generators with dual fuel turbines (gas/diesel), double 66kV overhead lines to 4 major remote sites, 400 major devices (transformers, breakers, motors, etc) Entire power system is controlled by ABB DCS - process controllers and runs fully automatic. Control includes: turbines, generators, breakers, transformers, subsystems etc. Number of wired I/O signals: Power Management System is a special group of dedicated programs in ABB DCS controller. Main functions are: monitoring interconnection status of the power system coordination of generators, frequency/voltage regulation calculation of consumption per load, island, area and site monitoring spare capacity of running generator sets load-shedding (disconnecting) preselected loads within 100ms disabling start of large loads if exceeding spare capacity monitoring and recording power consumption peaks warning and suggesting messages for the operator reports: production, consumption, running hours, peaks,... DCS Configuration Process controllers - AdvantController 450 (9 units) Operator stations - AdvantStation 500 OS (10 units) Information Management Station - AS500 IMS (2 units) X terminals - (2 units) Control network MasterBus 300, Plant Network TCP/IP, MODBUS serial links etc. 7 Power Management System - application development Process utilities (fuel gas, water treatment, instrument air, diesel fuel, etc.) - application design and development process controllers application design, programming and testing operator stations application design and customizing factory acceptance test with client wiring supervision, I/O check commissioning and start-up training for operation and maintenance personnel Application development, programming and commissioning, technical training Onsite baby sitting and extensive customer technical training Y2000 compliance survey and corrections Maleh extension adding AC450 controller in a new location System extensions to support new G4 generator Tanak extensions system modifications to support new equipment in Tanak location System extensions to support new G5 generator