MACH 2 060202 - ABB Ltd · 9 The sub-cycle analysis action within MACH 2 is based on decades of engineering efforts. Already in the early 1970´s ABB engineers mastered SVC control

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MACH 2Knowledge Based Control System For FACTS

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FAQ´s on “Performance” : How fast is the MACH 2 program execution?

How is performance achieved ?

What input does MACH 2 need?

What reaction time can one achieve with MACH 2?

Can performance be recorded ?

Performance: Yes of course, but what if something strange happens?

FAQ´s on “Payback”: Where is the added value in MACH 2 ?

What is standard and what is optional ?

What are the o&m costs ?

What can I save using MACH 2 ?

FAQ´s on “Face to Face” : How is the hardware within a MACH 2 system confi gured ?

What within MACH 2 is tailored for each specifi c FACTS installation ?

How is the software documented and administered?

What philosophy is built into the HMI ?

What can an operator “play with” ?

What protocols can MACH 2 handle for connection to SCADA ?

FAQ´s on “Help Desk” : As a customer, what can I expect when MACH 2 fails?

What level of trouble shooting can I, as a customer do myself ?

How can ABB help ensure availability over a long period?

FAQ´s on “Evolution” : How long will MACH 2 be on the market?

Who else uses MACH 2?

How long can I buy spare parts?

Frequently Asked Questions

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MACH 2 is a knowledge based control system dedicated to power applications

Control algorithms built on unequalled know-how

Field proven worldwide

Modular structure

User friendly high-level engineering tool

Windows based

Fault tolerant, but built with redundancy in mind

High degree of operational safety

Protected access

Complete self-diagnostics

Industrial grade concept

Open secure interfaces

One c&p platform for all FACTS

Built to be and stay compatible – with older c&p generations on the market – when future upgrades are needed

A Century of Knowledge

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WATCHANALYSEEXECUTEFILES

ANALYSE Perform

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MACH 2Knowledge Based Control System

No CD?Order it at

www.abb.com/FACTS

EXECUTE

WATCH24hrs 365days

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Watch

Johan Hedman– Manager, Software Design

”We have over 300 MACH 2 installations in the world. Together they watch and guard power provided to over 3 billion people. I am proud to know that our systems are doing their job in the background every second, 24 hrs a day, all year around for a long time to come”.

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Can we see FACTS as a watchdog? Yes, if it is equipped with MACH 2 we can. MACH 2is a true voltage watchdog, keeping track of grid voltages at critical buses, where many electricity consumers rely on adequate voltage quality. MACH 2 can within a fraction of a cycle detect an abnormal voltage and direct the FACTS installation to counteract. In order to do this correctly, ABB has developed data acquisition techniques that optimally capture the voltage disturbances, whether they originate from electric arc furnaces, lightning strokes, railway feeders or stalling induction motors. Using sophisticated data acquisition algorithms, we still rely on robust voltage and current measuring apparatuses, locally available at the FACTS installation site, which are easy to implement in the grid.

The computing capacity of MACH 2 also makes it suitable to act as “relay protection” for the FACTS installation. There is an obvious advantage here, as the MACH 2 protection algorithms can be tailored to the often-unique waveforms that appear within the high voltage circuit of a FACTS installation.

In specifi c applications, where extremely low fault tolerant FACTS installation is required, two redundant MACH 2 units share the duty, each with its own measuring circuits. This philosophy is easily justifi ed in cases where a malfunction within the FACTS installation put a larger grid at risk, or would stop a complex industrial process. MACH 2 has also been developed and optimized with redundancyin mind.

ANALYSISthrough MACH 2knowledge base

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The sub-cycle analysis action within MACH 2 is based on decades of engineering efforts. Already in the early 1970´s ABB engineers mastered SVC control theory. In the 1980´s we implemented Series Capacitor protections in microcomputers. Over the recent decade new products like Thyristor Controlled Series Capacitor (TCSC) and SVC Light® have challenged us, with ever higher requirements on processor speed and memory capacity.

MACH 2 is a platform housing the accumulated know-how from hundreds of ABB FACTS installations worldwide. ABB has met more customers than any competitor, hence we have faced almost every FACTS trap there is. We have made the mistakes and learned from them. Our patented TCSC control algorithms were developed in the Brazilian jungle, as we tried to interconnect two grids in the vast country. Numerous electric arc furnaces around the world have been test-benches. ABB’s fl icker mitigation algorithms have lead to the present unequalled performance in fl icker reduction. Our synchronizing circuits have seen all kinds of real harmonics, voltage sags, swells and interrupts. Laboratories

are there of course, but what characterizes the FACTS fi eld is that almost every installation is somewhat unique. It is because we have stayed in the FACTS fi eld for more than 30 years that we have the engineering edge. Continuity and curiosity are the keys.

Anders Frost– System Design

Being into the business for years, as a senior power engineer, it is a fortune to work on a daily basis with the software engineers matching the MACH 2platform with the standards and policies set by the power industry today. Together with the demands of easy-usage and reliability from our customers this job is always very fascinating. Today, we have reached a point in our design were ABB can offer a tailor-made platform for FACTS and HVDC applications with a high level of reliability, security and speed.

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Anders Persson – Sales and Marketing

“ABB is the most experienced FACTS supplier in the world with many dedicated engineers that have been working for years to obtain today’s robust design and outmost performance of our applications. From that perspective, it is great to be able to offer this wide and sharp technical knowledge programmed into the MACH 2 platform”.

In a FACTS application, the muscles can be the power semiconductors that control the very high currents, (e.g. in a thyristor valve), or the by-pass circuit breaker in a Series Capacitor. Typically every critical execution cycle within MACH 2 is followed by tens of Mvars being exchanged with the grid. Thousands of Amperes are turned ON or OFF say every tenth of a second!24/7/365! Safety and accuracy in the execution could not be more important so we’d better make sure the foregoing analysis is correct. Power semiconductors can do wonders but they should be handled with care. They serve, but they can also fail within milliseconds.

So computing speed becomes important in FACTS applications. 50Hz (60) might not sound like a high frequency, but the events that FACTS installations are designed to counteract are unpredictable and/or stochastic. This means that the embedded information has to be captured instantly and timed with the possible execution intervals. MACH 2 is built for this and its built-in dedicated signal processors and programmable arrays execute within a small fraction of a cycle. In fact, we are using Pulse Width Modulation (PWM) switching at 1650Hz in order to eliminate arc furnace fl icker. This execution speed thus becomes another key to unequalled FACTS performance, made possible by the know-how behind it. Thirty years are compressed into a few milliseconds.

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FILESMACH 2 fi les all eventsto add knowledge

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A FACTS installation is a large investment and is also expected to last a long time, thirty years at least. By its nature it is highly dynamic in its action (but totally static by defi nition). It might be tempting to see it as a black box, and we have to admit that many do so. But the black box will tell you what is has been through. MACH 2 is standardly equipped with a built-in Sequential Event Recorder (SER), a database type of software residing in the Operator Work Station (see Face-to-Face section). This will provide more accurate information about events in the FACTS installation, what would be the case with a standalone SER. The resolution of the built-in SER is down to one millisecond and its capacity well covers all relevant signals within a FACTS installation.

In order to get the whole picture from events, especially those unwanted ones (trips, disturbances), information about the pre-event operational status of the FACTS installation is often invaluable. MACH 2 can optionally be confi gured with Transient Fault Recorder software (TFR). Again this built-in database will provide the utmost accurate information about the pre-event status, and eliminate the need for standalone TFR equipment. The TFR capacity is expandable to the extent that it covers the range of signal for each specifi c FACTS installation.The built-in SER and TFR provide the best way to know what has happened. The information is easy to share, as the database format is compatible with various analysis tools, and you can see the performance.

Anna Jonsson– After Sales Support

“MACH 2 is a fascinating tool for a reliable performance of our application. The platform enables self-monitoring and trouble shooting capabilities. If necessary, ABB’s in-house technical expertise can connect from remote for easy problem solving and effi cient support to the customer, regardless of the physical location of the installation”

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What’s in it for me?

Buying a MACH 2 control system, either as part of a FACTS installation or standalone as an upgrade of an existing SVC or Series Capacitor, will minimize your risk. The risk could be power quality problems like fl icker from (your) arc furnaces or voltage collapses in (your) grid. The risks will be more apparent when the furnaces and grids are operated closer to their capacity limits, possibilities come alongside risks.

But you can have the possibilities without the risks. FACTS controlled by MACH 2 provides robustness and readiness, the grid and furnaces can be utilized harder and the reliability will even be raised.

So the decision is whether to buy the best insurance available.MACH 2 track records are unrivalled here, it will perform at its best when the grid going gets tough. Don’t leave the grid without it.

How much is a descision worth? MACH 2 makes thousands of decisions a second, every one has to be right...

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MACH 2 is a concept, intended to optimize the performance of a FACTS installation over a long period. You can still buy the computer only, but there are built-in tools that provide added value, such as:

• Remote Access Service (RAS), use your ordinary telephone line to check the status at the FACTS site.

• Sequential Event Recorder (SER), keeps track of everything that happens within the FACTS installation. The only true story.

• Transient Fault Recorder (TFR), stores the waveforms at events as the FACTS installation sees it.

• Gateway Station (GWS), communication interface that speaks the common languages used e.g. within SCADA systems.

• FACTS Online, a local server computer that will act as the web homepage for the FACTS installation. Let ABB supervise (your) FACTS over the web.

We market these adders as options (SER is a standard feature) but we should think laterally. They can replace standalone devices and eliminate investment and operation and maintenance costs for these. The information is taken right at the sources and it is readily available in a convenient format. The philosophy is that not only should the time and resources needed to keep the MACH 2 in good shape be negligible in comparison, but the MACH 2 should also make sure that any event around the FACTS installation is captured, understood, and correctly and safely remedied.

MACH 2 will pay you back, the quicker the more grid related problems you experience. And there are options to make sure it is always available and reachable, options that minimizes the o&m costs for the FACTS installation over time. If you want ABB to be with you 24/7/365, we can do that too, over the Internet.

More than a control and protection system

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Face to Face

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Control and supervision of apparatuses within the FACTS plant, circuit breakers, capacitor banks, disconnectors. Point-on-wave switching. Integratedprotection of apparatuses.

Control and supervision of thyristor and IGBT (through PWM) valves. Fiberoptical communication with the high voltage circuit.

Control and supervision of FACTS plant auxiliary systems, like valve cooling and auxiliary power distribution.

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From the MACH 2 platform a specifi c control&protection confi guration is tailored for each specifi c FACTS application. The scope of plant interfaces are determined and the control algorithms are (if needed) adapted to the specifi c application scenarios outlined in the customer specifi cation. The sequential logics are programmed to match the switchgear installed for the FACTS installation. The specifi ed level of redundancy is confi gured, dual MACH 2’s are optionally used in cases where a FACTS outage must not be caused by control error.

The tailoring of a specifi c MACH 2 system takes advantage of ABB’s huge portfolio of in-service FACTS plants. The knowledge gained from meeting and satisfying numerous customers guides the engineering process all the way from specifi cation to fi eld verifi cation and testing. The software platform is fl exible and user friendly, but it also administers the program code with strict discipline. A true knowledge based process.

Each MACH 2 delivery is carefully tested before shipment. Factory Acceptance Tests are regularly performed, where controls, sequences and protections are verifi ed against models of high voltage grids and disturbing loads. Often in front of the customer.

Your MACH 2

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Lars Smedhag– Software Development

“MACH 2 is among the most fl exible and modular high performance control and protection platforms from ABB. The integration level is exceptional as you can run an entire FACTS plant’s control and protection in one computer if desired. The many built-in options makes external Transient Fault Recorders, Sequence Event Recorders and Remoter Terminal Units obsolete, as these functions can easily be integrated modules into the fl exible HMI structure”.

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Face-to Face

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Control – fi eld proven, often patented algorithms to assure optimal dynamic performance from your FACTS installation.

Adapting Modules

Software discipline is a key success factor. MACH 2 programs are modularized, with the modules carrying the experience and knowledge. Depending on the type of FACTS installation, its confi guration and rating, different modules are adapted and linked to form a consistent application program. The program is documented on a user-friendly functional level and perfect coherence is assured as the fi nal code is compiled.

Sequences – safe and reliable logics for simple dispatch of the FACTS installation.

Interface – local and remote. MACH supports the following protocols for remote control and monitoring: IEC 870-5-101 and –104, DNP3.0 level 2, DNP over TCPIP, ModBus RTU, ModBus TCPIP, CDC type II, RP 570, RP 571.

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Support – Support can be adapted to the need of the client. There is a service called FACTS Online with three agreement levels: Support, Care and Carefree. This support exists within the ABB FACTS organization and is also part of the construction or upgrade of an installation. More information about FACTS Online is available in a separate brochure or you can fi nd a pdf fi le on the CD provided on page 5.

Supervision – assuring consistency in the FACTS high voltage circuit, the auxiliary systems, as well as within the MACH 2 itself.

Protection – tailored for FACTS operating conditions.

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The customer operator or engineer will not need to “play with” his FACTS installation very often. Its very nature is such that it shall do its job alone, it stays unmanned and a remote operator keeps a distant eye on it. But when some local human action is needed, the Human Machine Interface (HMI) of the MACH 2 must be built to facilitate quick action without errors.

The HMI views driven by the MACH 2 Operator Working Station (OWS) appear “Windows-like”, easy to recognise and remember, the information is only a mouse-click away. The FACTS installation is represented with a tailored overview diagram (single line) from which it is dispatched. The operator will instantly know what is going on. Safe “two-hands-select-execute” command philosophy is built into every operator sequence, whether it is a disconnector that is to be opened or a control parameter that shall be changed.

All texts on the HMI views are written in English and the specifi c language of destination. Important messages shall not be misunderstood. Access to the HMI views can also be restricted using different pass-words such that the amount of information is limited to a relevant level for each user.

Human Machine Interface

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FACTS with full control and operator in command is assured by presenting:

• status of switchgear apparatuses• bus voltages and branch currents• status of individual thyristors or IGBTs• status of input and output circuits• status of individual platform computers• vital control setpoints• status of valve cooling system• trend curves of FACTS performance

Single-Line-Diagram

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Fault, alarm, and eventlist

Thyristor Supervision Cooling system Supervision

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ABB has provided FACTS installations equipped with computerized controls for twenty years. We have secured the software with the utmost discipline. We have selected and minimized the hardware complexity. We have reused as much as possible and tested, and tested, and tested…

We have done this for years, and we are truly good at it. However, something within MACH 2 could still go wrong.

That is why it must not be used as a black box!

The MACH 2 concept is also built with the troubled customer in focus. ABB has established different levels of support in order to facilitate fault diagnosis and trouble shooting. Down-times must be minimized!

The following straightforward recommendations should be considered by every MACH 2 user:

• keep a complete set of spare circuit boards

• keep the fault tracing documentation readily available

• keep the responsible personnel trained

As a rule ABB delivers FACTS installations, complete with spares, documentation and training packages. As a market leader we do this often and we have done it for a long time! Our experience and knowledge is also built into our support. The result is that an alert and trained customer, with the help of the information on the HMI status views and the plant documentation, quickly identifi es a failed circuit board, replaces it andreestablishes the FACTS operation.

Recommendations

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Computers often come with “helpdesks” and so does the MACH 2. ABB has developed support capabilities in the form of Remote Access Services (RAS). Using these, an ABB FACTS specialist can get in contact with the MACH 2 computers in the FACTS installation. In simple form this takes place over a telephone modem. In this way, it is possible for ABB tocheck the status of the processors and its peripheral electronics within MACH 2. Trouble shooting becomes a team effort. But we do not always like telephone circuits.

Support for users is provided by ABB over the Internet. We call it FACTS Online. This business concept is based on Internet communication. Implementing FACTS Online will grant the FACTS user continuous support from ABB. The support service levels can differ, but they are all based on ABB FACTS specialists being automatically notifi ed (over the internet) upon alarms and/or trips within the FACTS installation. ABB will also (over a mail-server at the customer) have Internet access to a specifi c MACH 2 web-server, which acts as a “mirror computer”.

By mirroring data from the MACH 2 control unit there is a safe way to be online with the MACH 2, meaning that an alarm will initiate action from ABB’s FACTS specialists. Given permission from the user customer, it is also possible to change parameters, check recorded data, and perform advanced trouble shooting. Using the Internet as communication media provides the necessary data transfer speed to make this a realistic possibility.

The ultimate level of FACTS Online would grant that ABB provide around-the-clock alert specialist support for your MACH 2 equipped FACTS installation. In this case, the “helpdesk” might know before you do!

But if it’s not that easy...?

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Computers retire quicker than FACTS installations. Is it so?

Yes, but No!

ABB has been a FACTS supplier for more than 30 years, standing out as the one the others benchmark themselves against. Continued success has made it possible to maintain a very high level of consistency also in our capabilities to handle older generations of equipment. Specifi cally for our control&protection systems we take pride in always helping a customer that needs to update from outdated equipment.

MACH 2 will also be retired but with grace. When it does we will see a smooth transition rather than a revolution. MACH 2 is based on an industrial PC platform and the Windows operating systems. We see these as pedestals also for the future and we will carefully introduce new versions of application software, add-in circuit boards and service tools.

Will this last for decades?

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The installed base of MACH 2 systems is large, as it is used for FACTS and HVDC applications. Hundreds of systems will be put on the market over a period of about 10 years or so. The driving force to keep these in good shape over time is obviously strong.

So MACH 2 will evolve as necessary to stay in the business. It is inherently built to create a minimum of transition troubles. ABB then guarantees that the components can be bought many years after their retirement. And when they can not, we plan to fi nd a future controller compatible with your MACH 2.

Only a company that stays in business can credibly claim this.

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ABB Power Technologies ABFACTSS-721 64 VästeråsSWEDENTel +46 (0)21 32 40 00Fax: +46 (0)21 32 48 10www.abb.com/FACTS

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Documents

MACH 2 060202 - ABB Ltd · 9 The sub-cycle analysis action within MACH 2 is based on decades of engineering efforts. Already in the early 1970´s ABB engineers mastered SVC control