Kariba South Power station

Exisiting Pilot cable interconnection

Control Desk

28 pair 28 pair 28 pair 4x 38 pair 6x38 pair 6x20pair(new) Sub Station

Intakes Stn Tx1 Stn Tx3 220vdc,380v, Machine Machine GTX

Junction Junction Junction 11kv,aux junction control marshaling
box 1 box box Junction boxes(6 suite ( 6 kiosks
boxes (4 off) off) Off)

Intakes
Junction
box 2

Fig1 –Existing Pilot Cable Connection Overview

Kariba South Power station

Pilot cable interconnection

Control Desk

38 Pair

Machine remote 2core Unit Tx Co2

control Junction
Equipment
box
19core 7core

19 core 30core

Generator
ACB local Turbine AVR cubicle
Relay
control Panel/MCS (disconected) on
panel
Cubicle refurbishment

Fig 2 .Existing Machine Pilot Cable Interconnection

(1) 55m 19core
18kV
Switchgear

18kV (2) 48m 19core

Protection

(3) 39m 2 x 27core

Excitation
Control
Suite
This allows for installation
1 x 19 of any extra relays to give the required
Sequencer (4) 10m 1 x 27core volt-free contacts No 7 4*27core or(6 x 27, ) core
New Relay S800 Remote
Panel
Panel 4m 134cores MIN
Input /Output
Unit

(5) 10m 19core

Turbine
Panel

New (6) 8m 10core 14 TWISTED PAIR SHEILDED CABLES

Annunciato FROM TRANSDUCERS- ANALOGUE INPUT
r SIGNALS

Existing 37core
Fig 3 proposed interconnection for Unit signals and the S800 I/O
Remote
control
junction Box
Figure 1: System layout
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable interconnection

Station Computer Old Control

Emergency Desk/Board
board

AF100 28 Pair

S800 JB’s 1&2 Relay

Remote panel
Stn Tx1 remote
I/O unit #1 ST
control Junction
box (RCJB)
Analogue signals
19core 2core

30 core 3x3core

Marshaling
ACB local Transformer hall Vent Plant control
Kiosk
control fire protection (disconected)
Cubicle Equipment

Fig 3 Stn Tx Pilot cable interconnection

Page 6 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable interconnection

Station Computer Old Control

Emergency Desk/Board
board

AF100 28 Pair

S800 JB’s 3&4 Relay

Remote panel
Stn Tx3 remote
I/O unit #2 ST
control Junction
box (RCJB)
Analogue signals
19core 2core

30 core 3x3core

Marshaling
ACB local Transformer hall
Kiosk
control fire protection
Cubicle Equipment

Fig 3 Stn Tx Pilot cable interconnection

Page 7 of 20
 Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable Interconnection

Emergency board

Stn Computer

28 Pair

Tail race Lake Level

Level transducer No1 Intakes Water Level
3core
transducer remote control transmitter( not
Junction box in use)
19core 28 pair

19 core 19core

No1 intake
No3 intake No5 intake NO2 Intakes
gate house
gate house gate house remote control
junction box

Fig 4 .Intakes Pilot Cable Interconnection

Page 8 of 20
 Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Proposed Pilot Cable Interconnection

Stn Emergency control board Sub station

Computer remote
console
Auxil
Relay Panel #1 iaries Relay Panel #2 Unit
Sub Station
S800 S800
I/O I/O
(6off)

220vdc,380v, 220vdc,380
Intakes Stn Tx1 11kv,aux Stn Tx3 v,11kv,aux Machine Machine GTX
Junction Junction Junction Junction Junction junction control marshaling
box 1 box boxes1&2 box boxes3&4 boxes(6 suite ( 6 kiosks
off) Off)

S800 I/O
Intakes
unit for Gen
Junction
Tx’s
box 2

Fig1 –PROPOSED Pilot Cable Connection Overview

Page 9 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable interconnection

Station Computer Emergency

Board
Control Desk

AF100
38 Pair
Relay
S800 JB#2 Panel
Remote
#1
I/O unit
N01 Junction box 4core 220v Dc
switchboard
Analogue signals
19core 2core
7core
2 x 19 core 9core

North
CSTx 1 SStn Tx1 Switchgear
Bank Mulsifier Fire
Relay relay Panel Compressor
Feeder Protection
Panel Panel
Turbine Hall

Fig 5 .220v, 380v, 11kv, and Auxiliaries Pilot Cable Interconnection 1

Page 10 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable interconnection

Station Computer Emegency Old Control Desk

board

AF100 38 Pair
Relay
panel#1
S800 JB1
Remote
No
I/O unit ST 2 Junction Box
Analogue sinals

19core
7 core
19 core 19 core

Stn Tx1
PC1 Relay 11 KV bus Section
Relay
panel relay Panel
Panel

Fig 6 Fig 2 .220v, 380v, 11kv, and Auxiliaries Pilot Cable Interconnection 2

Page 11 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable interconnection

Emengency board/Control
Old Control Desk
Desk
Stn Computer

38 Pair
AF100
Relay
panel #2
S800 JB4
No3 Junction box
Remote I/O
unit
S800 I/O Analogue signals
mudule 19core

19 core 7core 19core

KN2 feeder
PC2 feeder Stn tx 3 11kv co2
Relay panel relay panel Equipment

Fig 7 Fig 2 .220v, 380v, 11kv, and Auxiliaries Pilot Cable Interconnection 3

Page 12 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Kariba South Power station

Pilot cable interconnection

Emegency Control
Board/Desk Old controlBoard/Desk
Stn Computer (Control Room)

38 Pair
Relay
AF100
panel #2
S800
Re
No4 Junction box
Remote I/O JB3
unit
(auxiliaries Analogue signals
) 2x19core 2x 7core

2x19 core 2x7core

CSTx 2
CSTx 3 380v Bus Vent feeder
Relay Panel
Relay section relay Panel
Common
Panel Relay Panel
services
PC2 feeder
Fig 8 Fig 8 .220v, 380v, 11kv, and Auxiliaries Pilot Cable Interconnection 4

Page 13 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Yelow
#5 Yellow
#3 Yellow
#1 Yellow phse
phse
Red phse Blue marshaling
marshaling
marshaling kiosk
kiosk
kiosk

S800 I/O for gen Tx

monitoring

Page 14 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Typical connection for digital inputs

Remote control Control

Plant Junction box Desk

50V dc + 50vdc-

Indiction/ existing
Alarm contact indication/alarm

Interposing Digital input Ix

Relay
S800 Remote I/O
Unit

Page 15 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Option1. Old control desk alarms and indications retained. Extra burden on power supply due to relay coil

Typical connection for digital inputs

Remote control Control

Plant Junction box Desk

50V dc + 50vdc+ 50vdc-

Indiction/ existing
Alarm contact indication/alarm

Interposing Digital input Ix

Relay
S800 Remote I/O
Unit

Page 16 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Option 2. Old control desk alarms and indications retained. Separate power supplies for interposing relays and control desk indications

Typical connection for digital inputs

Remote control Control

Plant Junction box Desk

50vdc+ 50vdc-

Indiction/ existing
Alarm contact indication/alarm

Digital input Ix

S800 Remote I/O

Unit

Page 17 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Option 3 Plant contacts now volt free. Old control desk indications decommissioned

Typical connection for digital outputs. (Control commands)

Old Remote control Control

Plant Junction box Desk

Interposing relay 50vdc+

50vdc-

220v Control ccts

or Input Terminals
on sequencer
50vdc+
Af100 bus
50vdc-

Digital output
Relay DOx

S800 remote I/O

Unit

Page 18 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Option 1 Old controls retained as backup.

Typical connection for digital outputs. (Control commands)

Remote control Control

Plant Junction box Desk

Interposing relay 50vdc+

50vdc-

220v Control ccts

or Input Terminals
on sequencer
50vdc+

50vdc- Af100 bus

Digital output
Relay DOx

S800 remote I/O

unit

Page 19 of 20
Appendix 3- Station Automation – Proposed interconnection of Remote I/O units

Option 1 Old controls decommissioned.

Page 20 of 20