Power Generation and Distribution - Control Systems

Thermal

Al Qaim (Iraq)

Al Shemal (Iraq)

Jorf Lasfar (Morocco)

Petkim (Turkey)

Power Generation and Distribution AUTOMATION

Hydro

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

INTEA d.d. - Av. V. Holjevca 27, HR-10020 Zagreb, CROATIA tel: +385 1 3436 200 fax: +385 1 7898 860 e-mail: [email protected] http://www.intea.hr

Power Generation and Distribution

Hydro Power Plants

Aswan High Dam - Egypt

About the Control System Scope

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: 10200.

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.

About the Plant 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, 15.75 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

INTEA Scope • 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

INTEA Chronology • 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.

• 2005-2010., 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.

17 Repeat

Orders



Hydro Power Plants

Kidatu - Tanzania

About the Control System 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.

About the Plant Kidatu Dam is Tanzania's largest Hydro Power Plant.

Total generating capacity: 200 MW

No. of units: 4 HD

INTEA Delivery Scope 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.

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 Repeat

Orders

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.



Hydro Power Plants

Kihansi - Tanzania

About the Control System 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).

About the Plant Total generating capacity: 180 MW

No. of units: 3 (Pelton turbines)

Facility has been in operation since December 1999. 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.

INTEA Scope • 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)

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.


Hydro Power Plants

Three Gorges - China

INTEA Scope • DCS design documentation - specifications for Information

Management System

• process controllers - "Transit node" application design,

programming and testing


• site support - technical expertise

INTEA Chronology • 2001 - Information Management System specification

• 2002 - Design and development of "Transit node" - ABB

AdvantController 450 application to support and manage data

communication

• 2002 - Documentation and technical training for end-user's

personnel

• 2005 - Site intervention - technical support

4 Repeat

Orders

About the Plant 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

18200 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.



Hydro Power Plants

NEK - Bulgaria

INTEA Scope • Distributed control system - SW design specification and other

documentation



• SW lead engineering and coordination

INTEA Chronology • 1998 - DCS SW - project leading

INTEA’s work was recognized, by ABB project management as

outstanding and highly professional.


Power plants are controlled by ABB DCS - process controllers and

run fully automatic. Control includes: turbines, generators,



Configuration



• Information Management Stations - AS500 IMS (3 units)

• Control network MasterBus 300 and Plant network TCP/IP


About the Plants NEK system project covers 3 hydro power plants:

• Belmeken (375MW),

• Momina Klisura (120MW) and

• Sestrimo (240MW).



Hydro Power Plants

Ertan - China

9 Repeat

Orders

About the Plant 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 1991. 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.


Power plants are controlled by ABB DCS - process controllers and

run fully automatic. Control includes: turbines, generators,


Configuration





• Information Management Stations - AS500 IMS (3 units)



INTEA Chronology • 1997. F.A.T. with the client

• 1999. Application development

• 2000. Intervention, communication problems analysis

• 2000. Control system upgrade

• 2004. Control system upgrade

• 2006. Site interventions and technical support

• 2007. System extensions, interventions and technical support

INTEA Scope INTEA took part in:



• communication troubleshooting intervention

• control system upgrade, extension and modifications



Hydro Power Plants

Karun I - Iran

2 Repeat

Orders


Power plant is controlled by ABB DCS - process controllers and

runs fully automatic. Control includes: turbines, generators,



Configuration



• Operator stations - UNIX based PC (5 units)



INTEA Chronology • 1999. Application development

• 2001. F.A.T., technical training for the client, commissioning

INTEA Scope INTEA took part in:


• F.A.T. with the client

• technical training for client's operation and maintenance

personnel

About the Plant Location: Karun river, Iran

Operator: Khuzestan Regional Electric Power

Configuration: 8 X 250 MW Francis

Operation: since 1976.



Hydro Power Plants

Yali - Vietnam

3 Repeat

Orders

INTEA Scope • DCS site survey




• DCS commissioning


INTEA Chronology • 1999. - technical trainig for clients personnel

• 2001. - site survey

• 2002-3. - DCS commissioning



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


Configuration




• Control network MasterBus 300, Plant Network TCP/IP


About the Plant 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 2001. The 69 meter-high

dam was sealed in 1996. The 64.5 km2 reservoir was filled by

1998. Yali HPP is composed of 4 units totaling 720 MW and high-

voltage 500kV switchyard (6 lines).



Hydro Power Plants

MANANTALI - Mali



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


Configuration




• Control network MasterBus 300, Plant Network TCP/IP


About the Plant 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 m3 and a surface of 477km2.

200MW 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).

INTEA Scope • process controllers application design, programming and testing



INTEA Chronology • May 2000 – August 2000, process controller and operator station

- application design, programming and FAT with the client.



Power Generation - Circulating Water System

Thermal Power Plants

Al Qaim - Iraq

INTEA Chronology INTEA is present on Al Qaim SCP plant since 2003. Even before

the project start, INTEA was engaged in site survey and finding

optimal solutions for steam turbines control system modernization.

About the Plant 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.

About the Control System 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 Scope 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.


Power Generation - Circulating Water System


Al Shemal - Iraq

2 Repeat

Orders INTEA Chronology • 2002. Control system design, final design project documentation

• 2004. Distributed process control and supervision system,

integration, programming, testing and equipment delivery.

INTEA Scope • 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


• "As manufactured" - documetation delivery

About the Plant 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


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.


DCS Configuration

• Process controllers - AdvantController 800M (8 units)

• Operator interface - Process Panel 245 (2 units)

• Control network and Plant Network TCP/IP.


Power Generation - Process Utilities


Jorf Lasfar - Morocco

3 Repeat

Orders INTEA Chronology • 1999. application design, programming and commissioning

• 2001. “coal handling” – intervention, program modifications,

system maintenance

• 2005. program modifications & commissioning

INTEA Scope Process utilities - control and supervision system:



• commissioning

About the Plant Jorf Lasfar power plant consists of 4x330 MW coal-fired/steam-

based turbo-generators. With total production capacity of 1320MW

this is the largest independent power plant in Africa.

About the Control System ABB DCS Configuration

• Process controllers - AdvantController 450

• Process controllers - AdvantController 160

• Operator stations - AdvantStation 500 OS

• Control network MasterBus 300, Plant Network TCP/IP.


Gas and/or Diesel Power Plants

Nouadhibou - Mauritania

5 Repeat

Orders INTEA Chronology • 2009. Control System Upgrade

• 2010. Delivery of additional HW

• 2011. Control System Extension



About the Plant 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


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;


INTEA Scope 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.



Centrale de Boulaos - Djibouti

16 Repeat

Orders

INTEA Scope 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.

INTEA Chronology Most significant DPP Boulaos projects:

• 1999. Commissioning and system optimizing

• 2005. DCS visualization system upgrade

• 2007. Integration of G22 in the DCS

• 2011. 800xA extension and training

• 2013. DCS extension - G24 alarms

• 2016. Upgrade of 4 x ABB AC110 to 4 x ABB AC160

About the Plant 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

About the Control System 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.




OMAR - Syria


Entire power system is controlled by ABB DCS - process

controllers and runs fully automatic. Control includes: turbines,

generators, breakers, transformers, subsystems etc.


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



• Information Management Station - AS500 IMS (2 units)

• X terminals - (2 units)

• Control network MasterBus 300, Plant Network TCP/IP,

MODBUS serial links etc.

About the Plant 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)

INTEA Scope • Power Management System - application development

• Process utilities (fuel gas, water treatment, instrument air, diesel

fuel, etc.) - application design and development




• wiring supervision, I/O check

• commissioning and start-up


INTEA Chronology • 1996. Application development, programming and

commissioning, technical training

• 1998. Onsite – “baby sitting” and extensive customer technical

training

• 1999. “Y2000” – compliance survey and corrections

• 2000. “Maleh extension” – adding AC450 controller in a new

location

• 2000. System extensions to support new G4 generator

• 2002. “Tanak” extensions – system modifications to support new

equipment in Tanak location.

• 2003. System extensions to support new G5 generator

7 Repeat

Orders


Documents

Power Generation and Distribution - Control Systems