HPP Kidatu (4x50 MW) - Control System Upgrade AUTOMATION

Transcription

1 HPP Kidatu (4x50 MW) - Control System Upgrade AUTOMATION

2 Location - Plant - End User About Location Kidatu is a town in southern Tanzania, located in Kilombero district, Morogoro region. The local population is about About the Plant Kidatu dam is located in Rufiji River Basin in Tanzania. Kidatu power plant was built in two phases under the name of Great Ruaha Power Project. Phase I was completed in 1975 and phase II in 1980, resulting in bigger storage dam at Mtera with a capacity of 3200 million cubic metres and full generating capacity of 200 MW. The plant has undergone two major rehabilitation works completed in 1994 and Kidatu power plant contributes about 36% of the total TANESCO hydro-installed capacity. KIDATU location About End User Tanzania Electric Supply Company Limited (TANESCO) is a state owned organization under Ministry of Energy and Minerals. The Company generates, transmits, distributes and sells electricity to Tanzania Mainland and sells bulk power to the Zanzibar Electricity Corporation (ZECO). TANESCO owns most of the electricity generating, transmitting and distributing facilities in Tanzania Mainland. Kidatu Dam Hydro Power Plant Total generating capacity: 200 MW No. of units: 4

3 The Project Name Complete project as specified by TANESCO was named: "Capacity building and emergency repair of TANESCO Kidatu hydropower plant in Tanzania", Purpose Purpose of the project was to overhaul critical mechanical and electrical parts of the plant to ensure reliable and safe plant operation, using full installed capacity, while keeping the project's costs at minimum. Scope The project included the following: MECHANICAL EQUIPMENT Cooling water and drainage: replacement of most equipment in two drainage pits ELECTRICAL EQUIPMENT Control system upgrade Governor: trouble-shooting and corrective actions Installing electronic governors for units 1 and 2 Replacement/refurbishing of: - MV (11kV switchyard), - LV (400V distribution system), - UPS (110V DC System) TRAINING Technical training Main Contractor Main contractor was Telenerg Ltd based in Zagreb - Croatia. Completion The project was successfully completed, on time, in May Control System Upgrade Summary 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.

4 The Control System About the Control System 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. This control system was initially installed and commissioned in period Common overall automation functions and system management are implemented in Station Controller. Generating units, auxiliary systems, switchyard and dam all have dedicated process controllers. Related backup systems enable operation of generating units without SCADA and process controllers. Overview The system controls and monitors: 4 generating units, Auxiliary PS, Auxiliary building, Switchyard, Dam, Overall Station functions. All communication between the different parts of the control system is carried out by standard and open international data communication protocols. The specific configuration of the data communication ensures necessary level of reliability, as well as high precision of events time stamping. The control system's main components are: process controllers with local and remote I/O, operator panels, data communication equipment, SCADA system.

5 Kidatu Hydro Power Plant Main Control System Architecture CONTROL ROOM Operator Workplace 1 Operator Workplace 2 Administration Engin. Workplace STATION Controller SWITCHYARD Controller Comm. 48V cable Powerh./Sw.yard FO Printer SCADA Client 1 SCADA Client 2 SCADA Servers 1&2 PG SIMATIC S7-300 AUX BUILDING Controller FO SIMATIC S7-300 UNIT 1 Controller UNIT 2 Controller UNIT 3 Controller UNIT 4 Controller AUX PS Controller FO GPS clock OP OP OP OP SIMATIC S7-300 STANDBY BUILDING SWITCHYARD BUILDING SIMATIC S7-300 SIMATIC S7-300 SIMATIC S7-300 SIMATIC S7-300 SIMATIC S7-300 TURBINE FLOOR ET200U remote I/O ET200U remote I/O ET200U remote I/O ET200U remote I/O ET200U remote I/O UNIT 1 UNIT 2 UNIT 3 UNIT 4 LEGEND: OP - Operator Panel FO - Fiber Optic PG - Programming Device SCADA - Supervisory Control and Data Acquisition Profibus DP electrical Fiber Optic cable Ind. Ethernet electrical Office Ethernet electrical DAM Controller SIMATIC S7-300 DAM SITE Auxiliaries

6 Control System Upgrade 2015 Process Controllers - Migration S5 > S7 All of the 9, obsolete, SIEMENS Simatic S5 Process controller's CPUs and communication modules were replaced with SIEMENS Simatic S7-300 CPU modules, featuring integrated Profibus DP and Industrial Ethernet/Profinet communication ports. Profibus DP is used for communication to I/O modules and Industrial Ethernet/Profinet for communication to operator panels, other process controllers and SCADA. Existing S5-135U I/O modules installed in the central controller and extension unit racks were reused in the new system by installing one Profibus DP slave interface module per rack, which converts the racks to Profibus DP I/O stations. Existing ET200U remote I/O modules installed in cubicles on generator and turbine floor and existing Profibus media converters were reused as Profibus DP I/O stations. Existing Station Controller was completely replaced by the new S7-300 CPU and I/O modules. Existing Step5 application was converted/upgraded to Step7. Required "Joint control" functionality was added/implemented in the "Station Controller" process controller. One Siemens color graphic touchscreen operator panel was added and connected to each Unit controller CPU, via Industrial Ethernet/Profinet communication. These operator panels are used as backup control system for supervision during tests or manual operation from relay board. New programming device (PG) was supplied, running on a dedicated PC, with Step7 and WinCC Comfort software packages for configuration, commissioning and troubleshooting of process controllers and operator panels.

7 Control System Upgrade 2015 Communication between Process Controllers and SCADA Industrial Ethernet/Profinet is used for communication between process controllers and with the SCADA system. Remote controllers (Switchyard and Dam) are not treated as RTUs (as in the old control system), but as equal process controllers connected over existing fiber optical links to the same control network as the other controllers. This simplifies the system configuration and maintenance. Nodes in the Power Station are interconnected using copper links while remote controllers are connected to the control network over fiber optics and media converters. Existing fiber optic cables are used for communication to remote controllers. Communication redundancy is achieved by connecting industrial Ethernet switches in a redundant loop providing a backup data transmission route if the cable is inadvertently disconnected or damaged. In addition to fiber optic link between Power Station and Switchyard a backup communication link is configured using Ethernet extenders with DSL technology and existing twisted pair signal cables. Central plant clock using GPS time signals is used for highly accurate time synchronization. It distributes the time to all systems to be synchronized, using NTP procedure over industrial Ethernet. In case of failure of the clock antenna, the central plant clock continues to provide reliable clock control, due to automatic changeover to highly accurate quartz operation. Switching back to remote clock control is also automatic and bumpless.

8 Control System Upgrade 2015 SCADA System SCADA is an operator control and monitoring system, used for visualization and operation of processes and plants. The old SCADA IGSS32 v2 was upgraded to the latest version of the same software package. The SCADA is based on PCs with Microsoft operating systems and client/server technology. Ethernet network enables communication between clients and servers. SCADA system consists of two servers and two clients (operator workplaces), running on PC workstations. Operator workplaces have two monitors, while two servers share one monitor via KVM switch. Two servers are used for SCADA system redundancy in order to ensure system availability and reliability. Industrial Ethernet/Profinet is used for communication to process controllers. Laser color printer is used for printout of process and trend displays, reports and event messages.

9 Operator's Screen Example

10 Operator Panels - Screen Samples UNIT1-4 Operator Panels Local operator panels enable alternative/backup monitoring and control of generating units 1-4, even if the SCADA system is out of function.

11 lntea - Delivery Scope Engineering Services Project management Design engineering control system functional design specification software design specification site/construction related drawings and instructions control system documentation: cabinet construction drawings, database and program listings, wiring diagrams, operating and maintenance manuals, etc. FAT procedures onsite works descriptions and procedures final as-built documentation Application engineering application engineering of process controllers application engineering of operator panels internal test in INTEA premises FAT During the Factory acceptance test all necessary tests were carried out to verify that the complete system delivery is in accordance with contract specification and requirements. The tests have included the following: visual inspection, functional tests, full demonstration of the application software. Onsite training The training was provided for client's engineers in order to teach them how to maintain and modify the control system. The training course covered fundamentals, system architecture, hardware, software, configuration, programming and maintenance aspects. Site works The following onsite activities were included in the scope of supply: loading SW application to process controllers, testing of controller's application, support in testing of the communication to SCADA. Hardware & Software Delivery The scope of supply included delivery of the following equipment and software: Process controllers, operator panels, engineering 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.

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