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Power Roadshow - Indonesia Importance of Excitation in Power Plants

Importance of Excitation Systems in Power Plants

Indonesia Power Roadshow

© ABB Group - 1 19-Mar-08

UNITROL®

Jakarta, March 25 2008

Pedro Lopez Automation Products Asia Network, Regional Sales Engineer

Excitation Systems

Content

Basics Of Excitation Systems Duties & Functionalities of Excitation Systems Benefits of Retrofitting

© ABB Group - 2 19-Mar-08

Product Portfolio

1

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

The Power Station CONTROL ROOM

HV SYSTEM

STEP UP TRANSFORMER

LV SWITCHGEAR AC & DC AUXILIARY SYSTEMS

HV- BREAKER

CONTROL SYSTEMS

2 AUX. TRANSF .

GOVERNOR

1

PROTECTION

GENERATOR BREAKER

1

2

PT’s & CT’s

SYNCHRONIZING

© ABB Group - 3 19-Mar-08

EXCITATION SYSTEM

SYNCHRONOUS GENERATOR

TURBINE

STAR POINT CUBICLE

Excitation Systems

STATIC STARTER

EXCITATION TRANSFORMER

Basics of Electrical Power Generation - Review

Conversion

© ABB Group - 4 19-Mar-08

Primary Energy

Mechanical Energy

Electrical Energy

Turbine

Generator

Transmission

Consumers

Excitation System

2

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Main Types of Synchronous Machines

Stator

Rotor

Stator

Rotor

Hydro-Generator

Turbo-Generator

For low rotation speed < 1500 U/min

For Steam and Gas Turbines

For Hydro Turbines

© ABB Group - 5 19-Mar-08

For high rotation speed > 1500 rpm

Excitation Systems

Basics of Excitation Systems Ug (AC Output Voltage)

AIR-GAP

If (DC Current)

+

_ ROTOR Excitation system

© ABB Group - 6 19-Mar-08

STATOR

3

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Content

Basics Of Excitation Systems Duties & Functionalities of Excitation Systems Benefits of Retrofitting

© ABB Group - 7 19-Mar-08

Product Portfolio

Excitation Systems

Functionality – Closed Loop Regulation

Controlled Object I

f

Electrical Generator

Ug

No-Load

© ABB Group - 8 19-Mar-08

Excitation System

4

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Behavior of a Generator Connected to the Network

© ABB Group - 9 19-Mar-08

WHAT HAPPENS WHEN WE CONNECT THE GENERATOR TO A LOAD OR NETWORK?

Excitation Systems

Network Complexity

The Network: Many Generators and Loads 2

1

External reactance

Tie

Infinite bus voltage

Xe 3

UNet

Regional grid

© ABB Group - 10 19-Mar-08

Substation

Power station T95_0157.D RW

5

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Functionality – Closed Loop Regulation Circuit

Controlled Object I

f

Electrical Generator

Disturbance Ug

Network

© ABB Group - 11 19-Mar-08

Excitation System

Excitation Systems

Behavior of a loaded Machine

Uf

Ug

© ABB Group - 12 19-Mar-08

Load

Sudden load change in an isolated system ( without AVR - Uf constant )

6

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Regulation of Generator Terminal Voltage U2

AVR

Pulse Generation

PID 1 1+TR Ug = k *

KR*

* n = k1 * If * n

Uc

(1+TC2)*(1+TC1) (1+TB2)*(1+TB1) TR=0.02 s TS=0.004

1 1+TS

If = Ud / Rf

SM

alpha 10°el © ABB Group - 13 19-Mar-08

kg 1+Tg

90°el

Ud=1.35*U2*cosalpha - delta U Uc

150°el

Excitation Systems

Power Chart with Operation Limits Under-excited (capacitive)

1

Driving Limit

Rotor Current Limiter Minimum Field Current Limiter

δ

-1

Limiter: P/Q Limiter

Stator Current Limiter

Ifn

-Q

Over-excited (inductive)

+P

Stability Limit

Generator

IGn ϕ

1 p.u. = nominal

The excitation system keeps the generator within thermal and stability limits

1 +Q

1 xd

Protection: Rotor over current inverse time

Motor © ABB Group - 14 19-Mar-08

Thyristor Converter

Ug Measuring

Loss of excitation protection

-1

-P

7

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Superimposed Control

a) POWER FACTOR Control +P [MW]

Cos

= 0.8

b) REACTIVE POWER Control -Q

+Q [MVAR]

© ABB Group - 15 19-Mar-08

-P

Excitation Systems

+P[MW]

+Q[MVAR]

-Q

Q = 0.2 p.u

Stable Distribution of Reactive Power

© ABB Group - 16 19-Mar-08

Generators directly connected to the same Busbars

8

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Power System Stabilizer – PSS Disturbance: • Load variation • Load rejection • Short circuits etc.

Turbine Excitation system Reference value U ref + -

PSS AVR

If

Voltage Regulator

Ug

~

+

+ U Grid

Grid

Generator

Analogy: Mechanical oscillation circuit Damper Dm

Mass

M2

© ABB Group - 17 19-Mar-08

M1 K (spring) X (distance)

Excitation Systems

Transient Stability during large System Disturbances Impact of Excitation System on Power System Stability

Grid Short Circuit Point Busbar

M

Short Circuit with acting of Excitation System (stability remained)

k1xUg ⋅ k 2 * Ep ⋅ sin δ Xd ' k1 = 0.3.....0.6 k 2 = 1.6....2.5 ME =

Before Short Circuit (stable Condition)

ME =

MA

Ug ⋅ Ep ⋅ sin δ Xd

δ © ABB Group - 18 19-Mar-08

AVR Generator 1

Short Circuit without acting of Excitation System (stability lost)

k1xUg ⋅ Ep ⋅ sin δ Xd ' k1 = 0.3.....0.6 ME =

9

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Available Prot. & Monitoring Functions

Monitoring and Protection Thyristor conduction monitoring DC short-circuit Loss of actual value (PT failure) Overcurrent Volts per Hertz Loss of excitation Rotor temperature Rotating diode failure (add. hardware required) Earth fault protection

© ABB Group - 19 19-Mar-08

Etc.

IARV / UNF11 E CHIND / 612

Excitation Systems

Internal & External Communication/HMI Control system

World Outside

© ABB Group - 20 19-Mar-08

HMI

10

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Modern Excitation Functionalities Overview PLANT COMPUTER CONTROL SYSTEM CMT-Tools Control Terminal Local or Remote

MODBUS PROFIBUS

MODEM

FIO Basis

FIO Extension

TCP/IP

AVR - Channel II AVR - Channel I

CONVERTER 4 CONVERTER 3 CONVERTER 2

MUB (Measuring Board)

COB (Control Board) AVR; Limiters; PSS

CONVERTER 1

Converter Electronics

Uc

Monitoring

CIN (Converter Interface)

Protection

Dynamic Current Distr.

Field Current Regulator

GDI (Gate Driver Interface)

Logic Control Converter Display

EGC (Extended Gate Controller)

© ABB Group - 21 19-Mar-08

(Option)

FIELD FLASHING FIELD SUPPRESSION

SM

Excitation Systems

Content

Basics Of Excitation Systems Duties & Functionalities of Excitation Systems Benefits of Retrofitting

© ABB Group - 22 19-Mar-08

Product Portfolio

11

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Excitation Lifecycle Management Excitation LCM aims at optimized maintenance Active development and sales phase

Classic product maintenance phase

Limited service support phase

Obsolete

© ABB Group - 23 19-Mar-08

no viable service market or technology remains Product and services have been released for sale by ABB (PRU) Continuing search for functional enhancements Support upgrade and/or replacement from older products (limited & obsolete) to active version

Product is no longer actively sold by PRU, but complete modules still available for most products from sPRU Enhancements available as technology permits Price may increase due to lower volume, increased vendor component costs, etc.

Product manufacturing is no longer supported by R&D Spare part availability continues as long as components are available Recommended replacement with Active Product Recycling Services are available where permitted

Product Support is no longer possible within reasonable cost ABB is no longer capable of supporting the product technically and/or old technology is no longer available Many ABB products have been and continue to be supported for over 20 years

Full Product Support Service Limited Product Support Service

Excitation Systems

Reasons for Retrofitting

Technology provided 20 years ago and more is obsolete Production of modules is usually difficult resulting in high costs and long delivery time Servicing know how is hardly available as the new generation of engineers dealing only with microprocessor technology The old AVRs normally require more spare parts, each module is dedicated to a function Missing functionalities: Power System Stabilizer Serial communication Comprehensive fault and data recording

© ABB Group - 24 19-Mar-08

Remote Access

12

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Power Seraya Gas & Steam Plants Retrofit Project

End user: PowerSeraya Ltd Location: Jurong Island, Singapore Generation:- Steam Plant: Stage I: - Steam Plant: Stage II:

3 x 250 MW 3 x 250 MW

© ABB Group - 25 19-Mar-08

- Steam Plant: Stage III: 3 x 250 MW - Siemens CCPP: 370 MW - Open Cycle Gas Plant: 2 x 20 MW

Excitation Systems

Power Seraya Steam Turbine Retrofit Project

© ABB Group - 26 19-Mar-08

Case 1: OLD Excitation System (before revamp):

13

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Power Seraya Steam Turbine Retrofit Project

NEW (after revamp) ABB Unitrol 5000: Proposed Excitation System according to the Technical Specifications The proposed Static Excitation System is shown on the attached single line drawing ATPE/91559A SL

© ABB Group - 27 19-Mar-08

Type designation – SES : A Dual AUTO channel (AUTO/AUTO), each incl. MAN controller 5 UNITROL 5000 (Microprocessor-based system 5000) S Standard n-1 redundancy O WithOut additional functions U5: U5 Thyristor converter, acc. to application requirements 2 2 converter bridges (n-1 redundancy) 1 1 Thyristor per bridge arm, 3-ph; 6-pulse D DC-breaker at converter output side 3100 Rated breaker current in Amps

Excitation Systems

Power Seraya Steam Turbine Retrofit Project

NEW (after revamp) ABB Unitrol 5000 1/4

© ABB Group - 28 19-Mar-08

ABB New Converters UNL14300 n-1 Configuration

CDP, UNS0885, Converter Display

14

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

High Power Thyristor Converter UNL14300

NEW (after revamp) ABB Unitrol 5000 2/4:

Input voltage: 720 - 1’500 VAC Output current: 2’600 - 4’900 ADC Fully redundant cooling fans Maintenance on-line Converter display for fast diagnosis

© ABB Group - 29 19-Mar-08

Modular design for easy paralleling for system currents up to 10’000 A

Excitation Systems

Power Seraya Steam Turbine Retrofit Project

NEW (after revamp) ABB Unitrol 5000 3/4:

© ABB Group - 30 19-Mar-08

ECT, Excitation Control Terminal Power Chart

15

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Power Seraya Steam Turbine Retrofit Project

NEW (after revamp) ABB Unitrol 5000 4/4:

© ABB Group - 31 19-Mar-08

GPS System

Excitation Systems

Power Seraya Steam Turbine Retrofit Project

Project Execution SCOPE: Turnkey Retrofit project (3 UNITS) that includes: => Retrofit Generator Control and Protection Systems => Retrofit Excitation systems => Training

Award of Contract:

20 Oct 2005

Completion of Commissioning of Unit 3: 17 May 2006 (completed within 6 wks) Completion of Commissioning of Unit 2: 7 July 2006 (completed within 4 wks)

© ABB Group - 32 19-Mar-08

Completion of Commissioning of Unit 1: Scheduled for end Sep 2006

16

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Benefits of Retrofitting to End-User

Advantages of Digital Technologies UNITROL 5000: All regulation, limiter, monitoring, protection and control functions and pulse generation are managed by two boards: Measuring Unit Board and Control Board. This implies: Considerable less number of modules Less spares Higher MTBF

Computer based diagnostic including: Commissioning and Maintenance Tools AVR-View; Remote diagnostic via Ethernet Serial Communication Link Remote diagnostic via Public Telephone Network

Integration into the Computer Control System via Serial Ethernet Modern control algorithms (e.g. Power System Stabilizer) improve transient stability and damping of the power swings. © ABB Group - 33 19-Mar-08

Local expertise & technical support

Excitation Systems

Content

Basics Of Excitation Systems Duties & Functionalities of Excitation Systems Benefits of Retrofitting

© ABB Group - 34 19-Mar-08

Product Portfolio

17

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Brands

® SYNCHROTACT SYNCHROTACT® ABB’s ABB’sbrand brandfor for Synchronization Synchronization Products Products

© ABB Group - 35 19-Mar-08

® UNITROL UNITROL® ABB’s ABB’sbrand brandfor for Excitation Excitation Systems Systems

Excitation Systems

Markets

New installations: Countries with large power plant potential, emerging markets Delivery to or co-operation with generator manufacturers

Modernization: For all kind of plants (e.g. nuclear, hydro, industry)

© ABB Group - 36 19-Mar-08

For all types of synchronous machines independent of brand (e.g. ABB, BBC, Alstom, Siemens, GE)

18

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Basic Types of Excitation Systems

Rotating Exciter

Static Excitation Supply of Power electronics (Shunt, PMG,auxiliary)

AVR AVR

E

SM

SM

© ABB Group - 37 19-Mar-08

1 to 200 A

100 to 10000 A + fast response time - brushes

+ brushless (mostly) - lower response time

Excitation Systems

UNITROL® AVR and Excitation Systems

© ABB Group - 38 19-Mar-08

UNITROL® 5000 SES

UNITROL® 5000 SES

UNITROL® 1000 AVR UNITROL® F SES

UNITROL® F AVR

19

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

UNITROL® 1000 AVR Family

Automatic Voltage Regulator for Synchronous Machines upto about 50MVA with rotating exciter Max. Output 40ADC and 300VDC Single channel or redundant configuration UNITROL 1000-PM40

UNITROL 1000-15

Power Module with 40ADC and 300VDC

15ADC and 300VDC Local HMI

Used together with UNITROL1000-15

UNITROL 1000-7 7ADC and 300VDC © ABB Group - 39 19-Mar-08

Limited no. of I/O‘s Without local HMI

Excitation Systems

UNITROL® 5000 Static Excitation Systems

Static Excitation Systems for synchronous generators for more than 10’000ADC Ifn

© ABB Group - 40 19-Mar-08

Example: Cold standby redundancy 1+1 redundancy)

Example: n-1 or n-2 redundancy

20

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

UNITROL® Product Range Excitation with rotating machine

Static Excitation System

Range of Application

® UNITROL UNITROL®5000 6000

UNITROL® F

© ABB Group - 41 19-Mar-08

UNITROL® 1000

Excitation Systems

40 A

500 A

>10’000 A

Ifn

UNITROL® 6000 – Static Excitation System AC800PEC controller - Fully compatible with ABB’s control platform Fiber-optic internal communication Perfect electrical isolation Highest EMC immunity Easy separation between control and power plant

© ABB Group - 42 19-Mar-08

Recommend: Optional withdrawable power converter modules

21

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

The heart of UNITROL 6000

Powerful ABB Power Electronics Controller 600MHz PowerPC CPU (IBM/Motorola)

© ABB Group - 43 19-Mar-08

64 bit IEEE floating point calculation

AC 800PEC Processor Module

Excitation Systems

Reference Example: Itaipu

Project: Itaipu HPP Extension (1x823MVA/50Hz; 1x737MVA/60Hz) Enduser: Itaipu Binacional 50Hz: IE = 4824A, Upl = 1474V 60Hz: IE = 3945A, Upl = 2350V Itaipu - The biggest HPP worldwide!

© ABB Group - 44 19-Mar-08

UNITROL 5000 System

22

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

References: Kousheng NPP / Taiwan Retrofit Delivery year: 2005 Customer: Taiwan Power Corporation Machine data: 2 x 1160 MVA Manufactured by Westinghouse Excitation data: Ifn = 90 A

© ABB Group - 45 19-Mar-08

Ufpl = 200 V

Excitation Systems

SYNCHROTACT® Synchronizers SYN 5302

SYN 5200 SYN 5201 SYN 5202

© ABB Group - 46 19-Mar-08

The SYNCHROTACT 5 Product Family

SYN 5100

SYNCHROTACT® HBT High Speed Busbar Transfer SYNCHROTACT® CSS Compact Synchronizing System SYNCHROTACT® MSP Modular Synchronizing Panel

23

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

Application Software ECT Software - Excitation Control Terminal (ECT) SW is a user-friendly tool for operation, monitoring and maintenance for UNITROL 5000 excitation systems. .

© ABB Group - 47 19-Mar-08

SMTS – Synchronous Machine Transient Simulation Allows the user to carry out simulations involving a synchronous machine in a very short time and in a very easy way.

Excitation Systems

SMTS-RT – Synchronous Machine Transient Simulation Real Time A notebook based real time synchronous machine simulator which allows real time closed loop tests for AVR’s.

ECT - Excitation Control Terminal CONTROL ROOM

© ABB Group - 48 19-Mar-08

FIBER OPTIC (UP TO 1000 m) OR TWISTED PAIR CABLE (UP TO 300 m)

SYSTEM MENU FAULT TRENDING LOGGER MENU MENU PARAMETER MENU OPERATION MENU POWER ALARM CHART MENU MENU

24

Power Roadshow - Indonesia Importance of Excitation in Power Plants

Excitation Systems

ABB University, Training center in Turgi

Modern training facilities including: 3 classrooms Laboratory Coffee Corner

© ABB Group - 49 19-Mar-08

Hands-on training using simulators and demo units plays an important role in our training methods

Excitation Systems

Our strengths

Worldwide presence of UNITROL specialists Local manufacturing/service presence in more than 10 countries Local availability of Spares Volume supplier

Customer Benefits Short response time

© ABB Group - 50 19-Mar-08

Knowledge of local market requirements

25

Power Roadshow - Indonesia Importance of Excitation in Power Plants

© ABB Group - 51 19-Mar-08

Excitation Systems

26