Power Roadshow - Indonesia

Importance of Excitation in Power Plants

Importance of Excitation
Systems in Power Plants Indonesia
Power Roadshow

UNITROL®
Jakarta, March 25 2008

Pedro Lopez
© ABB Group - 1 -

Automation Products Asia Network, Regional Sales Engineer

19-Mar-08

Excitation
Systems Content

Basics Of Excitation Systems

Duties & Functionalities of Excitation Systems
Benefits of Retrofitting
Product Portfolio
© ABB Group - 2 -
19-Mar-08

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems The Power Station
HV SYSTEM CONTROL ROOM

STEP UP
TRANSFORMER LV SWITCHGEAR

AC & DC
HV- BREAKER AUXILIARY
SYSTEMS CONTROL
SYSTEMS

2 1
AUX. PROTECTION
TRANSF
GOVERNOR .

GENERATOR
1 BREAKER 2
STATIC
STARTER

PT’s
&
CT’s
SYNCHRONIZING

SYNCHRONOUS EXCITATION
TURBINE GENERATOR SYSTEM
© ABB Group - 3 -

STAR
POINT EXCITATION
19-Mar-08

CUBICLE TRANSFORMER

Excitation
Systems Basics of Electrical Power Generation - Review

Conversion

Primary Mechanical Electrical Transmission Consumers

Energy Energy Energy

Turbine Generator

Excitation
System
© ABB Group - 4 -
19-Mar-08

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Importance of Excitation in Power Plants

Excitation
Systems Main Types of Synchronous Machines

Rotor Stator

Stator

Rotor

Turbo-Generator Hydro-Generator
For high rotation speed > 1500 rpm For low rotation speed < 1500 U/min
For Steam and Gas Turbines For Hydro Turbines
© ABB Group - 5 -
19-Mar-08

Excitation
Systems Basics of Excitation Systems

Ug (AC Output Voltage)

If (DC Current)
AIR-GAP

ROTOR
STATOR
Excitation system
© ABB Group - 6 -
19-Mar-08

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems Content

Basics Of Excitation Systems

Duties & Functionalities of Excitation
Systems
Benefits of Retrofitting
Product Portfolio
© ABB Group - 7 -
19-Mar-08

Excitation
Systems Functionality – Closed Loop Regulation

Controlled Object

I Ug
f Electrical
No-Load
Generator

Excitation
System
© ABB Group - 8 -
19-Mar-08

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Importance of Excitation in Power Plants

Excitation
Systems Behavior of a Generator Connected to the Network

WHAT HAPPENS WHEN WE

CONNECT THE GENERATOR
TO A LOAD OR NETWORK?
© ABB Group - 9 -
19-Mar-08

Excitation
Systems Network Complexity

The Network: Many Generators and Loads

2
1
External reactance Infinite bus voltage

Tie Xe

3 UNet
Regional grid

Substation
© ABB Group - 10 -

Power station
T95_0157.D RW
19-Mar-08

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems Functionality – Closed Loop Regulation Circuit

Controlled Object Disturbance

I Ug
f Electrical Network
Generator

Excitation
System
© ABB Group - 11 -
19-Mar-08

Excitation
Systems Behavior of a loaded Machine

Ug
Uf

Load
© ABB Group - 12 -
19-Mar-08

Sudden load change in an isolated

system ( without AVR - Uf constant )

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Importance of Excitation in Power Plants

Excitation
Systems Regulation of Generator Terminal Voltage

U2

Ug Pulse
AVR

Thyristor Converter
Measuring Generation

PID Uc

1 (1+TC2)*(1+TC1)
KR*
1+TR (1+TB2)*(1+TB1)
TR=0.02 s
Ug = k * * n = k1 * If * n TS=0.004
1
1+TS
If = Ud / Rf
SM
alpha
10°el Ud=1.35*U2*cosalpha
- delta U
kg
© ABB Group - 13 -

1+Tg 90°el Uc
19-Mar-08

150°el

Excitation
Systems Power Chart with Operation Limits
Under-excited +P Over-excited
(capacitive) (inductive) Limiter:
1
Rotor Current Limiter
Stability Limit

Driving Limit
P/Q Limiter

Minimum Field
Current Limiter
Generator
Stator Current Limiter
Ifn IGn
The excitation system
keeps the generator within
ϕ thermal and stability limits
δ

-Q -1 1 1 +Q
xd
Protection:
Rotor over current
inverse time
Motor
Loss of excitation protection
© ABB Group - 14 -
19-Mar-08

1 p.u. = nominal -1
-P

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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]
+P[MW]

-P -Q +Q[MVAR]
© ABB Group - 15 -

Q = 0.2 p.u
19-Mar-08

Excitation
Systems Stable Distribution of Reactive Power

Generators directly connected to the same Busbars

© ABB Group - 16 -
19-Mar-08

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Importance of Excitation in Power Plants

Excitation
Systems Power System Stabilizer – PSS
Disturbance:
Turbine • Load variation
• Load rejection
Excitation system • Short circuits
etc.
PSS
Reference value
U ref + If Ug + U Grid
AVR ~ + Grid
-
Voltage Generator
Regulator

Analogy: Mechanical oscillation circuit

Damper
Mass
Dm

M1 M2
© ABB Group - 17 -

K (spring)
19-Mar-08

X (distance)

Excitation
Systems
Transient Stability during large System Disturbances

Impact of Excitation System on Power System Stability

Short Circuit
Grid with acting of k1xUg ⋅ k 2 * Ep ⋅ sin δ
Excitation System ME =
(stability remained)
Xd '
Short Circuit Point M k1 = 0.3.....0.6
Busbar k 2 = 1.6....2.5

Before Short Circuit

(stable Condition)

Ug ⋅ Ep ⋅ sin δ
ME =
MA Xd

δ
AVR
Short Circuit
without acting of
k1xUg ⋅ Ep ⋅ sin δ
© ABB Group - 18 -

Excitation System ME =
Generator 1 (stability lost) Xd '
k1 = 0.3.....0.6
19-Mar-08

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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
Etc.
© ABB Group - 19 -
19-Mar-08

IARV / UNF11 E
CHIND / 612

Excitation
Systems Internal & External Communication/HMI
Control system

HMI
World
Outside
© ABB Group - 20 -
19-Mar-08

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Importance of Excitation in Power Plants

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

MODBUS FIO FIO

MODEM PROFIBUS Extension
Basis

TCP/IP

AVR - Channel II CONVERTER 4

CONVERTER 3
AVR - Channel I
CONVERTER 2
COB CONVERTER 1
(Control Board)
Converter
AVR; Limiters; PSS Uc Electronics
(Measuring Board)

Monitoring CIN
(Converter Interface)
MUB

Protection Dynamic Current Distr.

Field Current Regulator GDI

(Gate Driver
Interface)
Logic Control
Converter Display

EGC (Extended Gate Controller)

(Option)
© ABB Group - 21 -

FIELD FLASHING
SM
FIELD SUPPRESSION
19-Mar-08

Excitation
Systems Content

Basics Of Excitation Systems

Duties & Functionalities of Excitation Systems
Benefits of Retrofitting
Product Portfolio
© ABB Group - 22 -
19-Mar-08

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems Excitation Lifecycle Management
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)
© ABB Group - 23 -
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
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
Excitation LCM aims at
optimized maintenance
Active
development and sales phase
Classic
product maintenance phase
Limited
service support phase
Obsolete
no viable service market or
technology remains
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

to active version vendor component costs, etc. available where permitted Many ABB products have
been and continue to be
supported for over 20 years
19-Mar-08

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
Remote Access
© ABB Group - 24 -
19-Mar-08

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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: 3 x 250 MW
- Steam Plant: Stage II: 3 x 250 MW
- Steam Plant: Stage III: 3 x 250 MW
- Siemens CCPP: 370 MW
- Open Cycle Gas Plant: 2 x 20 MW
© ABB Group - 25 -
19-Mar-08

Excitation
Systems Power Seraya Steam Turbine Retrofit Project

Case 1: OLD Excitation System (before revamp):

© ABB Group - 26 -
19-Mar-08

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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

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)
© ABB Group - 27 -

1 1 Thyristor per bridge arm, 3-ph; 6-pulse

D DC-breaker at converter output side
3100 Rated breaker current in Amps
19-Mar-08

Excitation
Systems Power Seraya Steam Turbine Retrofit Project
NEW (after revamp) ABB Unitrol 5000 1/4

ABB New Converters UNL14300

n-1 Configuration
© ABB Group - 28 -

CDP, UNS0885, Converter Display

19-Mar-08

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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
Modular design for easy paralleling
for system currents up to 10’000 A
© ABB Group - 29 -
19-Mar-08

Excitation
Systems Power Seraya Steam Turbine Retrofit Project
NEW (after revamp) ABB Unitrol 5000 3/4:

ECT, Excitation Control Terminal

Power Chart
© ABB Group - 30 -
19-Mar-08

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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:

GPS System
© ABB Group - 31 -
19-Mar-08

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)
Completion of Commissioning of Unit 1: Scheduled for end Sep 2006
© ABB Group - 32 -
19-Mar-08

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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.
Local expertise & technical support
© ABB Group - 33 -
19-Mar-08

Excitation
Systems Content

Basics Of Excitation Systems

Duties & Functionalities of Excitation Systems
Benefits of Retrofitting
Product Portfolio
© ABB Group - 34 -
19-Mar-08

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems Brands

UNITROL
UNITROL®
® SYNCHROTACT
SYNCHROTACT®
®

ABB’s ABB’s
ABB’sbrand
brandfor
ABB’sbrand
brandfor
for for
Excitation
Excitation Synchronization
Synchronization
Systems
Systems Products
Products
© ABB Group - 35 -
19-Mar-08

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)
For all types of synchronous machines independent of brand
(e.g. ABB, BBC, Alstom, Siemens, GE)
© ABB Group - 36 -
19-Mar-08

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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

SM E SM

1 to 200 A 100 to 10000 A

© ABB Group - 37 -

+ brushless (mostly) + fast response time

19-Mar-08

- lower response time - brushes

Excitation
Systems UNITROL® AVR and Excitation Systems

UNITROL® 5000 SES

UNITROL® 5000 SES
© ABB Group - 38 -

UNITROL® 1000 AVR

19-Mar-08

UNITROL® F SES UNITROL® F AVR

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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 1000-15 UNITROL 1000-PM40

15ADC and 300VDC Power Module with
40ADC and 300VDC
Local HMI
Used together with
UNITROL1000-15

UNITROL 1000-7
7ADC and 300VDC
Limited no. of I/O‘s
© ABB Group - 39 -

Without local HMI

19-Mar-08

Excitation
Systems UNITROL® 5000 Static Excitation Systems

Static Excitation Systems for

synchronous generators for
more than 10’000ADC Ifn

Example: Cold standby redundancy 1+1 redundancy)

© ABB Group - 40 -
19-Mar-08

Example: n-1 or n-2 redundancy

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems UNITROL® Product Range
Excitation with
Static Excitation System
rotating machine

UNITROL
UNITROL®5000
®
6000
Range of Application

UNITROL® F

UNITROL® 1000
Ifn
© ABB Group - 41 -

40 A 500 A >10’000 A
19-Mar-08

Excitation
Systems 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
Recommend:
Optional withdrawable power
converter modules
© ABB Group - 42 -
19-Mar-08

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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)
64 bit IEEE floating point calculation
© ABB Group - 43 -

AC 800PEC Processor Module

19-Mar-08

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!

UNITROL 5000
System
© ABB Group - 44 -
19-Mar-08

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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
Ufpl = 200 V
© ABB Group - 45 -
19-Mar-08

Excitation
Systems SYNCHROTACT® Synchronizers

SYN 5302
SYN 5200
SYN 5201
SYN 5202

The SYNCHROTACT 5
Product Family SYN 5100

SYNCHROTACT® HBT
High Speed Busbar Transfer
© ABB Group - 46 -

SYNCHROTACT® CSS
19-Mar-08

Compact Synchronizing System

SYNCHROTACT® MSP
Modular Synchronizing Panel

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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. .

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.

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.
© ABB Group - 47 -
19-Mar-08

Excitation
Systems ECT - Excitation Control Terminal
CONTROL ROOM
FIBER OPTIC (UP TO 1000 m) OR
TWISTED PAIR CABLE (UP TO 300 m)

SYSTEM
FAULT
TRENDING
OPERATION
POWER
ALARM MENU
LOGGER
PARAMETER MENU
CHART MENU
MENU
MENU
MENU
MENU
© ABB Group - 48 -
19-Mar-08

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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

Hands-on training using

simulators and demo units
plays an important role in our
training methods
© ABB Group - 49 -
19-Mar-08

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
Knowledge of local market requirements
© ABB Group - 50 -
19-Mar-08

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Power Roadshow - Indonesia
Importance of Excitation in Power Plants

Excitation
Systems
© ABB Group - 51 -
19-Mar-08

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