Tobias Keller, Vice President Excitation Products & Technology, ATPE
ABB excitation and synchronization
A short introduction
ABB
3BHS335164 E01 Rev. E
© ABB Group
June 4, 2012 | Slide 1
Introducing ABB
ABB
ABB Switzerland Ltd
ABB
Power Electronics
Excitation business
Product portfolio
UNITROL®
UNITROL®
MEGATROL
MEGATROL
SYNCHROTACT®
SYNCHROTACT®
UNIREC
UNIREC
Software Tools
© ABB Group
June 4, 2012 | Slide 2
Introducing ABB
ABB
© ABB Group
June 4, 2012 | Slide 3
A global leader in power and automation technologies
Leading market positions in main businesses
135,000 employees in about 100 countries
$38 billion in revenue (2011)
Formed in 1988 merger of Swiss and
Swedish engineering companies
Predecessors founded in 1883 and 1891
Publicly owned company with head
office in Switzerland
100
2011
13.5
380
1988
1883
ABB
© ABB Group
June 4, 2012 | Slide 4
1891
Power and productivity for a better world
ABB’s vision
ABB
As one of the world’s leading engineering companies, we
help our customers to use electrical power efficiently, to
increase industrial productivity and to lower environmental
impact in a sustainable way.
© ABB Group
June 4, 2012 | Slide 5
Merging power and automation technologies
makes electricity network more reliable, flexible,
secure and efficient. Smart grid benefits include:
Lower power consumption
Greater use of renewable energy
ABB’s broad offering in both power and
automation technologies positions it uniquely to
support this evolution
Transformation of grid to take place over several
decades
ABB
ABB
© ABB Group
June 4, 2012 | Slide 6
Innovation is key to ABB’s competitive advantage
Leadership built on consistent R&D investment
ABB
*
More than $1.3 billion invested annually in R&D*
7,500 scientists and engineers
Collaboration with 70 universities
MIT (US), Tsinghua (China), KTH Royal Institute of Technology (Sweden), Indian Institute of
Technology (New Delhi), ETH (Switzerland), Karlsruhe (Germany), AGH University of Science and
Technology (Poland)
13
7,500
70
,
© ABB Group
June 4, 2012 | Slide 7
,
,
,
,
AGH
,
ABB Switzerland Ltd
ABB
© ABB Group
June 4, 2012 | Slide 8
ABB Switzerland Overview
ABB
Headquarters: Baden, Switzerland
Focus on
Overall solutions for utilities and industries
Power products
Automation products
Orders in 2011: CHF 3.36 billion
Revenues in 2011: CHF 3.57 billion
6,600 employees
2011
2011
6,600
: 33.6
: 35.7
ABB Switzerland Locations
ABB
Headquarters
1
12
Baden
Engineering/
production location
2
3 I
4 5 6
7
8
II
Lenzburg
11
/
1 Schaffhausen
2 Klingnau/
Kleindoettingen
3 Turgi/Untersiggenthal
4 Birr
5 Baden/Daettwil
6 Wettingen
7 Zurich
8 Lenzburg
9 Molinazzo di
Monteggio
10 Quartino
11 Deitingen
12 Birsfelden
13 Geneva
© ABB Group
June 4, 2012 | Slide 10
III
IV
13
10
9
Regional sales office
Baden
II Zuzwil
III Bern
IV Lausanne
V Pregassona
V
Power Electronics
© ABB Group
June 4, 2012 | Slide 11
Power Electronics and MV Drives
Business overview – Global Product Groups
Power Electronics
Traction
MV Drives
Excitation Systems
Power generation
Synchronous motors
High Power Rectifiers
Aluminum smelters
Chlorine electrolysis
DC arc furnaces
Traction DC substations
MV Power Converter Systems
17 Hz rail power converters
AC excitation
MV STATCOM
MV Power Converter Products
MV wind power converters
…
LV Power Converter Products
Active voltage conditioners
Battery and fuel cell converters
Marine frequency converters
© ABB Group
June 4, 2012 | Slide 12
BORDLINE
Propulsion converters
for trains and locomotives
BORDLINE
Auxiliary converters
for onboard power supply
BORDLINE
Battery chargers
ACS 1000 / 1000i
0.3 – 5 MW
ACS 5000
2 – 22 MW
ACS 6000
3 – 27 MW
MEGADRIVE-LCI
2 – 72 MW (or higher)
Metals
Mining&Minerals
Oil & Gas
Power
Marine
Water
Power Electronics and MV Drives
Global footprint and key locations
PRU OEM Packs
MVD Service Hub
LEC Excitation
LEC Rectifiers
LEC Power Conv.
Sales MV Drives
R&D MV Drives
LCC Factory in MX
PRU Excitation
PRU Rectifiers
PRU Power Conv.
LCC Factory in PL
PRU Traction Conv.
PRU MV Drives
PRU Service
Sales MV Drives
LEC Excitation
LEC Rectifiers
Sales MV Drives
© ABB Group
June 4, 2012 | Slide 13
Sales MV Drives
Sales MV Drives
LEC Excitation
LEC Rectifiers
LEC Traction
Assbly. MV Drives
LEC Excitation
LEC Rectifiers
Sales MV Drives
PRU
LEC
JV
LEC Excitation
JV Rectifiers
JV Traction
Assbly. MV Drives
LEC Excitation
LEC Rectifiers
Sales MV Drives
PRU LV Power Cv.
Power Electronics and MV Drives
Global center of competence (Switzerland)
ABB
ABB
, Turgi
ABB
ABB
Lenzburg
© ABB Group
June 4, 2012 | Slide 14
,
Dättwil
Power Electronics and MV Drives
Center of excellence
PE and MV Drives center in Turgi, Switzerland: ABB’s
center of excellence for power electronics and MV
drives
Single location with global responsibility
Research and Development
Sales and Marketing
Engineering and Project Management
Production
Service
Schaffhausen
Baden
Turgi
Daettwil
Birr
Zurich
Lenzburg
Number of employees
900
:
Berne
Lausanne
Geneva
© ABB Group
June 4, 2012 | Slide 15
Pregassona
900
Excitation business
© ABB Group
June 4, 2012 | Slide 16
ABB Switzerland
Global Product Line Excitation Systems
ABB
Aija Mankkinen
Assistant: I. Schwammel
Bahman Kazemi
Sergio Nienartowicz
Pierre Enstedt
Hans-Jörg Herzog
Tobias Keller
Rudolf Wieser
Michael Locher
Bangalore
Ramesh K.
Marketing Communication
Development & Support
Sales
Sales Service
Electrical
LEC Support
Product Management
Electrical Engineering
Operation Service
VAR Support
Mechanical Engineering
Product Sales
Project Management
Component Sales
Factory
© ABB Group
June 4, 2012 | Slide 17
Engineering
Mechanical
Engineering
Commissioning
Global Product Line Excitation Systems
Excitation Products and Technology
Tobias Keller
Stephan Egli
Peter Moor
Development & Support
Valerijs Knazkins
Tobias Keller
Georg Meier
Rudolf Moeckli
Matthias Bächle
Werner Zimmerli
Dietmar Ebner
David Stutz
Patrick Vandekerckhove
© ABB Group
June 4, 2012 | Slide 18
Product Management
Wolfgang Knapp
Product portfolio
© ABB Group
June 4, 2012 | Slide 19
Key solutions for power plants
HV system
Control room
Step up
transformer
LV switchgear
AC & DC
AUXILIARY
SYSTEMS
HV-breaker
2
Governor
1
Control systems
Aux. Protection
Transf.
Generato
r
breaker
1
2
Static starter
PT’s
&
CT’s
Synchronizing
Star
point cubicle
© ABB Group
June 4, 2012 | Slide 20
Excitation system
SYNCHRONOUS
GENERATOR
TURBINE
Excitation
transformer
Excitation systems and synchronizing equipment Brands
UNITROL®
Excitation systems
MEGATROL
Static frequency converter and
static excitation system in one package
SYNCHROTACT®
Synchronizing equipment
UNIREC
© ABB Group
June 4, 2012 | Slide 21
Main Generator Rectifier and Excitation
for on board DC-grid solutions
Excitation systems and synchronizing equipment
Production site (Turgi)
What ensures high quality and reliability of our products:
Professional skills of our workers
Collaboration with certified suppliers
All systems undergo 100% functional test before
leaving the factory
:
© ABB Group
June 4, 2012 | Slide 22
100%
References
Lungmen NPP / Taiwan
/
Customer: Mitsubishi Electric Corp.
End user: Taiwan Power Corporation
Machine data: 2 x 1,600 MVA
Manufacturer: Mitsubishi Electric
Excitation data: Ifn = 9,750 A / Ufpl = 1,392 V
:
:
: 2 x 1,600 MVA
New installation
Delivery year 2001
One of the largest
SES worldwide
© ABB Group
June 4, 2012 | Slide 23
2001
:
: Ifn = 9,750 A / Ufpl = 1,392 V
References
Itaipu HPP / Brazil - Paraguay
/
Plant extension
Delivery year 2003
The largest HPP
worldwide
–
Customer: Itaipu Binacional
2003
Machine data: 9 x 823 MVA / 50Hz,
9 x 737 MVA / 60Hz
Manufacturer: AAP
Excitation data: Ifn = 4,824 A, Ufpl = 1,474 V / 60Hz;
Ifn = 3,945 A, Ufpl = 2,356 V
:
: 9 x 823 MVA / 50Hz,
9 x 737 MVA / 60Hz
:
: Ifn = 4,824 A, Ufpl = 1,474 V / 60Hz;
Ifn = 3,945 A, Ufpl = 2,356 V
© ABB Group
June 4, 2012 | Slide 24
References
Longtan HPP / China
/
Customer: GEARI
New installation
Delivery year 2005
2005
Machine data: 7 x 778 MVA
Manufacturer: HEC / DFEM
Excitation data: Ifn = 3,493 A / Ufpl = 1,173 V
:
: 7 x 778 MVA
:
/
: Ifn = 3,493 A / Ufpl = 1,173 V
© ABB Group
June 4, 2012 | Slide 25
References
Haiyang NPP / China
/
Customer: Harbin Electrical Machinery Co. Ltd
Machine data: 1,600 MVA
Manufacturer: Harbin Electrical Machinery Co. Ltd
Excitation data: Ifn = 10,169 A / Ufpl = 1,018 V
:
: 2X1,250MW
:
New installation
Delivery year 2011
© ABB Group
June 4, 2012 | Slide 26
2011
: Ifn = 9, 265 A / Ufpl = 1,020 V
References
Sanmen NPP / China
/
Customer: Harbin Electrical Machinery Co. Ltd
Machine data: 2X1,250MW
Manufacturer: Harbin Electrical Machinery Co. Ltd
Excitation data: Ifn = 9, 265 A / Ufpl = 1,020 V
:
: 2X1,250MW
New installation
Delivery year 2011
:
2011
: Ifn = 9, 265 A / Ufpl = 1,020 V
(70%
© ABB Group
June 4, 2012 | Slide 27
Excitation systems
®
UNITROL
®
UNITROL
© ABB Group
June 4, 2012 | Slide 28
UNITROL excitation systems
Automatic voltage regulator system duties
Provide variable DC current with short time overload
capability
Control generator terminal voltage with suitable accuracy
Ensure stable operation with network and / or other
machines
E
AVR
Keep machine within permissible operating range
Contribute to transient stability subsequent to a fault
Communicate with the power plant control system
SES
© ABB Group
June 4, 2012 | Slide 29
UNITROL ®
UNITROL ® 1000 / UNITROL ® 6000
© ABB Group
June 4, 2012 | Slide 30
Excitation systems
®
UNITROL 1000
UNITROL
© ABB Group
June 4, 2012 | Slide 31
® 1000
UNITROL 1000 product family
until end of 2011
UNITROL ® 1000
2011
UNITROL 1000-15
© ABB Group
June 4, 2012 | Slide 32
UNITROL 1000-PM40
Power module
UNITROL 1000-7
UNITROL 1000 product family
from February 2012
UNITROL ® 1000
2012 2
UNITROL 1010
UNITROL 1020
UNITROL 1000-PM40
(power module)
© ABB Group
June 4, 2012 | Slide 33
UNITROL 1000 product family UNITROL ® 1000
Hardware overview
UNITROL 1010
UNITROL 1020
10 A cont.
20 A ceiling
20 A cont. *
38 A ceiling
Aux power supply
YES
YES
Panel
NO
YES
8 digital I/Os
4 digital input
3 analog inputs
2 analog outputs
8 digital I/Os
4 digital input
3 analog inputs
2 analog outputs
USB
RS485
Ethernet
(CAN)
USB
RS485
Ethernet
(CAN)
IP20
Low module height
IP20
*) Ie > 15 A requires
external capacitor
Excitation current at 55
°C
55 °C
I/Os
I/O
Interfaces
Mechanicals
Mounted inside generator
© ABB Group
June 4, 2012 | Slide 34
Mounted inside generator
Excitation systems
®
UNITROL 6000
Product line
®
UNITROL 6000
© ABB Group
June 4, 2012 | Slide 35
UNITROL 6000 excitation systems UN6000
UN6080 control and converter UN6080
Compact converter and control unit
UN6080 AVR and SES
Single and redundant configuration
1)
1)
PIN6080
Channel#2
CCM6080
PIN6080
CCM6080
Channel #1
CIO
#1
CIO #1
1)
SM/SG
Discharge
© ABB Group
June 4, 2012 | Slide 36
Field
flashing
UNITROL 6080
UNITROL 6000 excitation systems
UN6080 AVR, 25-60A indirect excitation
Thermal power plant
43.75 MVA / 10.5 kV
AVR
43.75 MVA / 10.5 kV
AVR
© ABB Group
June 4, 2012 | Slide 37
UNITROL ® 6000
UN6080 AVR, 25-60A
UNITROL 6000 excitation systems
UN6080 prepared to meet customer requirements
UN6080
Aux.Li
ne Hz
50/60
-Q71
-K71
Supply transfer
Aux.Li
ne Hz
50/60
Batter
y
Batter
y
-Q72
-Q71
-Q72
-K72
-K71
-K72
AC-field circuit
breaker
-T04
-T04
-F60 -Q80 -F63
-T60
-F60 -Q80 -F63
-T63
-T63
-T60
-Q03
-V80
-V80
Aux.
Power
-Q10
-Q20
-A10
-Q12
-Q30
-A20
CH 1
CH 2
-Q22
-R02
Aux.
Power
-Q10
-Q20
-A10
-A30
BFCR
CH 1
-Q32
-Q12
-A02
-Q30
-A20
CH 2
-Q22
Converter
protection and
on-line
maintenance
-A30
BFCR
-Q32
On-line
maintenance
S007
-Q02
-R08
MOV
R
02
- V T
02 02
DC-field circuit
breaker
© ABB Group
June 4, 2012 | Slide 38
UNITROL 6000 excitation systems
UN6080 single channel static excitation
Hydro power plant
7 MVA / 6.4 kV
SES
7 MVA / 6.4 kV
SES
© ABB Group
June 4, 2012 | Slide 39
UNITROL ® 6000
UN6080
Excitation systems
®
UNITROL 6800 medium
to large SES
®
UNITROL 6800
© ABB Group
June 4, 2012 | Slide 40
UNITROL ®
UN6800
UNITROL 6000 excitation systems
UN6800 controller and power converter
AC 800PEC controller
AC 800PEC
UN6800 SES
Measurement signals
Parallel converter operation
Optical data link
Thyristor gate control
Backup
control &
protection
Control
channel#1
Converter
Converter
control
Control
channel #2
I/O device
IO Device
IO Device
SG
Discharge
© ABB Group
June 4, 2012 | Slide 41
Field
flashing
UNITROL 6800 static excitation system
UNITROL ® 6800
© ABB Group
June 4, 2012 | Slide 42
UNITROL excitation systems
UNITROL ®
UNITROL 6800 controller technology UNITROL ® 6800
Powerful ABB power electronics controller AC 800PEC
Graphical software development with Matlab/SIMULINK RTW
IEC 61131 engineering software, ABB Control Builder
400 MHz Power PC CPU (IBM)
64 bit IEEE floating point calculation
ABB
AC 800PEC
Matlab/SIMULINK RTW
IEC 61131
600 MHz
64
© ABB Group
June 4, 2012 | Slide 43
IEEE
ABB Control Builder
Power PC CPU (IBM)
Excitation systems
UN6000 Summary
UN6000
© ABB Group
June 4, 2012 | Slide 44
UNITROL excitation systems product portfolio
Comparison major characteristics UN6080 / 6800
UN6800 static excitation system (SES)
UN6800
(SES)
Optional
UNITROL ®
UN6080 / 6800
UN6080 AVR and SES
UN6080 AVR
SES
Measurement signals
Measurement signals
Optical data link
Optical data link
Thyristor gate control
Thyristor gate control
to be used alternatively or both
1)
1)
Converter#1
Channel#2
PIN6080
BFCR
CCM6080
PIN6080
Converter
control
Control
Channel # 2
PIN6080
Control
Channel#1
CCM6080
Channel #1
CCM6080
Backup
control &
protection
I/O IO
device
Device
2
IO Device
CIO
#1
CIO #1
1)
SG
SM
Basic I/O
Direct hard wired
SM/SG
Discharge
Field
flashing
Discharge
UNITROL 6800
© ABB Group
June 4, 2012 | Slide 45
Field
flashing
UNITROL 6080
UNITROL excitation systems product portfolio
Comparison major characteristics UN6080 / 6800
UN6800 static excitation system (SES)
UN6800
(SES)
UNITROL ®
UN6080 / 6800
UN6080 AVR and SES
UN6080 AVR
SES
UN6080
UN6800
Single, double, triple redundant control
Single, double, triple redundant control
Up to 8 converters in parallel operation
n-1, n-2 (hot standby)
1 converter in operation
1 or 2 redundant converters
1+1 (cold standby)
Independent controller and converter
redundancy
Controller and converter operate as one unit
10 … 1,600 ADC
1,600 … 10,000 ADC
UN6800
n-2
UN6080
8
(
n-1,
)
1,600 … 10,000 ADC
© ABB Group
June 4, 2012 | Slide 46
1
1
2
1+1 (
)
10 … 1,600 ADC
Excitation systems
Power System Stabilizer
PSS
© ABB Group
June 4, 2012 | Slide 47
Power System Stabilizer (PSS)
Available types
(PSS)
Acc. to IEEE Standard 412.5 – 2005
Type PSS 2B
Single band PSS with fixed parameters
New - acc. to IEEE Standard 412.5 – 2005
Type PSS 4B
Multiband (MB) PSS with three individually adjustable bands dedicated to the low,
intermediate and high frequency modes of oscillations
Adaptive PSS
Self-tuning parameters based on present loading of generator and actual network conditions
IEEE Standard 412.5 – 2005
PSS 2B
IEEE Standard 412.5 – 2005
PSS 4B
PSS
(MB) PSS
PSS
PSS
© ABB Group
June 4, 2012 | Slide 48
Excitation systems
®
UNITROL operator
interface
UNITROL
© ABB Group
June 4, 2012 | Slide 49
®
UNITROL 6080/UNITROL 1020
Service Control Panel (SCP)
UNITROL ® 6080/
UNITROL ® 1020
(SCP)
Local operation of excitation system
Actual values (eg, UG, If)
Alarms and events
Event recorder
Parameter values and settings(eg, Vo, Ta)
(eg, UG, If)
(eg, Vo, Ta)
© ABB Group
June 4, 2012 | Slide 50
UNITROL 6080 / 6800
Excitation Control Terminal (ECT)
UNITROL ® 6080 / 6800
(ECT)
Benefits
W x D x H (mm)
483 x 355 x 90
Weight 7.3 kg
W x D x H (mm)
483 x 355 x 90
7.3 kg
Comprehensive data acquisition and
representation
Independent data storage
Simple and fast troubleshooting
Password protected access levels
Selectable languages
Features
Local and/or remote control terminal
Stand-alone industrial PC with 15" color
touch screen
/
15“
© ABB Group
June 4, 2012 | Slide 51
PC
UNITROL 6080 / 6800
Excitation Control Terminal (ECT)
© ABB Group
June 4, 2012 | Slide 52
UNITROL ® 6080 / 6800
(ECT)
MEGATROL
Package solution to start
gas turbines and excite
their generator
MEGATROL
© ABB Group
June 4, 2012 | Slide 53
MEGATROL system interaction
MEGATROL
SSD
Output power SSD
GT torque
Excitation current
Speed
t
Actual state:
SSD ON
Ignition
Field weakening
G
SSD OFF
EXC ON
© ABB Group
June 4, 2012 | Slide 54
Synchronizing
Excitation Current IEN /A
MEGATROL product Line
Static excitation current, SSD starting power
© ABB Group
June 4, 2012 | Slide 55
MEGATROL
, SSD
MEGATROL Light
Arrangement
© ABB Group
June 4, 2012 | Slide 56
MEGATROL
MEGATROL
© ABB Group
June 4, 2012 | Slide 57
DCS #2
DCS #3
Unit #3
Unit #1
DCS #1
DCS #4
DCS #5
Unit #5
MEGATROL
Cross start
DCS #6
Synchronizing equipment
®
SYNCHROTACT
®
SYNCHROTACT
© ABB Group
June 4, 2012 | Slide 58
SYNCHROTACT synchronizing equipment
Generator synchronizing and paralleling of lines
SYNCHROTACT®
U1
SYNCHROTACT
5
CMD
CB
U2
AVR
G
© ABB Group
June 4, 2012 | Slide 59
GV
U+
Uf+
f-
S 99003
SYNCHROTACT synchronizing equipment
Automatic synchronizer and synchrocheck
SYNCHROTACT ®
Synchrocheck
Automatic single channel synchronizing
device
Automatic dual channel synchronizing device
Redundant automatic dual channel
synchronizing device
© ABB Group
June 4, 2012 | Slide 60
SYNCHROTACT
Advantages and benefits
SYNCHROTACT ®
Highest security against incorrect paralleling
Redundant design with two brands of digital signal processors each with its
own software architecture
Highest availability with dual channel design
State-of-the-art communication (Modbus, Profibus, IEC61850)
Low engineering costs - all functions in one casing
Low commissioning costs - comfortable HMI, sophisticated PC tool
(Modbus, Profibus, IEC61850)
© ABB Group
June 4, 2012 | Slide 61
,
On board DC-grid
UNIREC
UNIREC
© ABB Group
June 4, 2012 | Slide 62
§
Onboard DC grid
Scope of Supply
© ABB Group
June 4, 2012 | Slide 63
/
Summary
UNIREC
UNIREC
Options UNIREC LV
© ABB Group
Month
DD,
|
Slid
GENREC-L
=> left side connection
GENREC-R
=> right side connection
Onboard DC grid
Overview Basic
© ABB Group
June 4, 2012 | Slide 65
Onboard DC grid
EXC and GENREC
EXC (Excitation)
© ABB Group
June 4, 2012 | Slide 66
GENREC (Generator Rectifier)
Software tools
© ABB Group
June 4, 2012 | Slide 67
UNITROL software products
ECT software, CMT 1000 tool
UNITROL ®
ECT
, CMT 1000
Excitation Control Terminal (ECT) SW
User-friendly tool for operation, monitoring and
maintenance of UNITROL 5000 and UNITROL
6000 excitation systems
(ECT)
UN5000
UN6000
CMT 1000 Tool
Commissioning and maintenance tool for UNITROL
1000. Enables controlling, monitoring, maintenance
and programming of the products
CMT 1000
CMT1000
UN1000
© ABB Group
June 4, 2012 | Slide 68
UN1000
UNITROL software products UNITROL ®
SMTS, SMTS-RT 6000
SMTS, SMTS-RT 6000
Synchronous Machine Transient
Simulation (SMTS)
The program allows the user to carry out simulations
involving a synchronous machine. SMTS includes
model of a turbine and a network.
(SMTS)
SMTS
Synchronous Machine Transient
Simulation Real Time (SMTS-RT 6000)
The tool enables real time simulation (for studies,
training and other purposes) and closed-loop tests of
the excitation systems.
(SMTS-RT 6000)
© ABB Group
June 4, 2012 | Slide 69
Synchronous Machine Transient Simulation
Simulation environment
© ABB Group
June 4, 2012 | Slide 70