FP_D.5_EGAT_THE REVAMP OF PARTIAL UPGRADE EXCITATION CONTROL SYSTEM BY USING THE EGAT s INNOVATION (EGAT-AVR)

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1 FP_D.5_EGAT_THE REVAMP OF PARTIAL UPGRADE EXCITATION CONTROL SYSTEM BY USING THE EGAT s INNOVATION (EGAT-AVR) 1. ABSTRACT Mr.Vitsanu Phonphai, (EGAT) vitsanu.p@egat.co.th Mr. Suwat Ratiwatcharakorn, (EGAT) suwat.rati@egat.co.th At present, many excitation control systems, which were used in EGAT s power plants, began to deteriorate and were lack of maintenance parts due to the increasing age of power plant and original equipment manufacturers (OEM) discontinued production line of the original model. They would affect the reliability of the power plant. This paper presents the revamping project of static excitation control equipment by partial upgrade of the analog controller parts which were replaced by the EGAT innovative excitation digital controller (EGAT- AVR). This paper describes the successful project, which was set up at Rajjaprabha Hydro power plant unit 2, with capacity of 89 MW. The new digital excitation controller (EGAT-AVR) was designed and developed by EGAT to replace the existing one. New features in HMI and local control panel display were designed for operating and maintenance, they led the operation more convenient compared to the existing system. The project consisted of design, installation and testing of excitation control system. The cost of import of the products and experts from original equipment manufacturers had been neglected in this project. In the future, the EGAT-AVR system can be expectably applied for other EGAT power plants. KEYWORDS: Excitation control, Digital control, Renovation 2. INTRODUCTION Static Excitation System is important equipment of the power plant. The exciter supply DC current to the rotor field winding of generator. It maintains the generator voltage, controls reactive power of generator, operates synchronous machine within limiting limit and prevents machine from being in asynchronous mode. Nowadays, there are a lot of analog static excitation equipment in EGAT power plants. The absence of spare parts is one of severe problems of power plant. It affects to reliability and productivity of electricity and may finally result in insufficient electricity for load demands. This project has been implemented to installed, tested and operated in Rajjaprabha hydro power plant unit 2, with capacity of 89 MW. Digital Excitation Controller (EGAT-AVR), was designed and developed by EMD team. This paper presents the partial revamping of static excitation system. The replacement of the existing analog controller by digital controller can mitigate problems easily. The designed digital controller is redundant system, which operate with the existing power converter. 3. DIGITAL EXCITATION CONTROLLER (EGAT-AVR) EGAT-AVR was developed by EMD team. The concept of development is Single Software - Multi Hardware that select hardware from reliable manufacturer and software development control based on IEC which is the international standard for programmable controller programming languages. PLC (Programmable Logic Controller), which was supplied by multiple manufacturers dealer in Thailand. Components is shown in display figure 1.

2 Figure 1. Hardware components 3.1 Main Controller The system processing core is SIMATIC S7-412H with redundancy CPUs; in the case of fault, changeover takes place from the master CPU to the standby CPU. The controller transfer is fast and bumpless control in case of fault. The redundant controllers are independent control, each controller has three control types: Automatic, manual and open loop sequence control mode. Either Master CPU and Standby CPU can control the bridge firing, as determined by operator or automatic transfer by the method of event-driven synchronization. 3.2 Generator Feedback Transducers The feedback signals are generator voltage, generator current, field voltage and field current. The generator feedback transducers were used to detect the feedback signals and convert to standard 0-10 Vdc at high speed to the analog input of controllers. The transducers consist of three elements; The generator voltage and current, active and reactive power and frequency is measured with PTCT transducer. the field current is measured with IEIF transducer by voltage across shunt resistor and secondary side current transformer of excite transformer techniques. The field voltage is measured with Vf transducer. 3.3 Gate Pulse Generator Modules The Synchronized 6- Gate Pulse Generator Modules were used to fire the six thyristors of a 3-phase, full controlled rectifier. The output of the modules is six pulses individually synchronized on 3-phase line-to-line voltages. The pulses are generated firing degree after the increasing zero crossings of the three line-to-line synchronization voltages. 3.4 Operator & Engineering Station Operator and engineering station such as the Human-Machine Interface (HMI) communicate with the static excitation system. The operator can monitor and control of the static excitation system, and engineering access to system diagnostic and control block library. 3.5 Power Converter The 3-phase, full-wave controlled rectifier is the power module. The rectifier can provide both positive and negative forcing field voltage for suitable performance. The power module is forced-air cooled. A temperature monitoring includes alarm and trip contact. Each SCR tray includes SCR monitoring and protection, such as snubbers and fuses. A conduction sensing detector, monitors each SCR Tray for blown fuse, lossing of gate pulse. 4. REVAMPING METHOD Improvements only EGAT-AVR Hardware Controller and remain existing power converter. Redundancy configuration is shown in Figure 2.

3 Figure 2. Structure Excitation Control System with Redundancy 4.1 Hardware Design Redundancy Controller The dual controller systems according to figure 3 is employed. For dual controller systems with automatic change-over to the back-up controller is very important to have an almost complete detection of controller failures in the excitation system. Figure 3. Controllers with redundancy

4 4.1.2 Redundancy I/O The I/O modules of master and back-up controller was connected with auxiliary relay through M1_DO01 and M2_DO01 diode respectively. In case of the master controller fails, the auxiliary relay (KXXX) is still operated with the back-up controller via M2_DO01 diode as shown in figure 4 Figure 4. I/O module with redundancy Redundancy Generator Feedback Signal Transducers The generator voltage and current from the PTs and CTs are wired to PTCT cards which act as signal conditioner to isolate and scale signal. Generator feedback signal transducer configuration is shown in figure Redundancy Gate Pulse Amplifier Figure 5. Feedback signal configuration The dual AGPM control firing angle of power converter. AGPM1 and AGPM2 were operate by Master controller and Back-up controller individually as shown in figure 6.

5 4.1.5 Redundancy Control Power Supply Figure 6. Pulse firing control with redundancy The power supply of Master controller and Back-up controller are 125 Vdc and 230 Vac respectively. In case of one of 125 Vdc or 230 Vac power supply fails, The controller still operate without redundancy as shown in figure 7. Out of 24 and 15 Vdc power supply is put together both of two power supply, therefore control supply and transducer supply is possible continue if one of 125 Vdc or 230 Vac power supply is working 4.2 Control Software Figure 7. Control power supply with redundancy Software is part of the program of control devices for the PLC and Human Machine Interface (HMI). We have developed an innovative EGAT-AVR control function library base standard IEEE421.5 ST1A. The advantage of control software supports the standard IEC

6 Figure 8. Control software and human machine interface 5. COMMISSIONING RESULT Figure 9. IEEE model ST1A During commissioning, the dynamic response test was performed. The step response, start-stop excitation and load rejection tests were accomplished. 5.1 Dynamic Step Response Test Figure 10 show the response of excitation control system to 5% step change of generator voltage in no load condition. Figure 11 show the response of load rejection at 81 MW 12.4 MVar. The excitation control system can successfully control generator voltage. Figure 10. Step response test

7 Figure 11. Load rejection test 5.2 Soft Start The mitigation of overshoot at the time of start-up is accomplished by soft start function. The generator voltage is built up to rated voltage by converter. The slow build-up is controlled by soft start ramp. Figure 12 show that the response of generator voltage at the time of start-up. 5.3 Controller Transfer Figure 12. Soft start Figure 13 show that the response of controller transfer, it smooth changed over either from auto mode of master controller to auto mode of back-up controller. Figure 13. Controller transfer

8 6. Summary This project was installed and commissioned at the Rajjaprabha hydro power plant unit 2, with capacity 89 MW in October The partial upgrade of the analog controller parts, was replaced by the EGAT's innovative excitation digital controller (EGAT-AVR). The Programmable Logic Control (PLC) Controller is applied for the processing core. The PLC has high reliability and support the standard IEC languages that make flexible in selective PLC manufacturers. The development program of the PLC by EMD team meets the standard IEEE (IEEE Guide for the Preparation of Excitation System Specifications) and IEEE (IEEE Recommended Practice for Excitation System Model for Power System. Stability Studies) which are an international standard. The EGAT- AVR can substitute for the existing system The revamping of excitation control system at Rajjaprabha hydro power plant unit 2 was operated very well. The EMD team improves Local Touch Panel and Human Machine Interface (HMI), the operators can use excitation control system easily than existing system. The maintenance and problem analysis of new excitation system are convenient for engineer. In the future, the EGAT-AVR system can be expectedly applied for other EGAT power plants 7. REFERENCES 1. IEEE Standard Definitions for Excitation Systems for Synchronous Machines IEEE Standard IEEE Guide for the Preparation of Excitation System Specifications IEEE Standard IEEE Recommended Practice for Excitation System Models for Power System Stability Studies, IEEE Standard Mr. Vitsanu Phonphai obtained a Bachelor s degree of Electrical Engineer from Prince of Songkhla University, Thailand in Since joining Electricity Generating Authority of Thailand (EGAT) in 2008, he has been with electrical machine control system section, department of electrical machine. He has experience in several works of excitation control system commissioning, operation and maintenance. His interested researches are power system stability and power plant control system consisting of governor and excitation control system using digital technology. Mr. Suwat Ratiwatcharakorn obtained a Bachelor s degree of Electrical Engineer from King Mongkut s University of North Bangkok, Thailand in Since joining Electricity Generating Authority of Thailand (EGAT) in 2007, he has been with electrical machine control system section, department of electrical machine. He has experience in several works of excitation control system commissioning, operation and maintenance. His interested researches are the field of embedded technology application and power plant control system consisting of governor and excitation control system using digital technology.

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