1 Raising automation level at a Swiss HPP
Raising automation level at a Swiss HPP Rene Neubert, Sales Director Valmet Automation
Felsenau HPP - more than 100 years in operation Owner: Energie Wasser Bern, EWB Location: Bern, river Aare, Switzerland Plant Data: 1909 3 Francis turbines, total 2,6 MW 1918 2 Francis turbines, total 4,5 MW 1989 Kaplan bulb turbine 11,5 MW, rest shut down Delivery scope for retrofit 2014: Valmet DNA control system Trend and Event Archive Turbine controller Water balance control Generator excitation Synchronization Power plant / River simulator Vibration monitoring & mechanical protection Electrical protection for Generator & Transformer
Customers requirements Challenge Development of the city of Bern and population increase has led to the steady increase in energy consumption. Outdated automation system was no longer reliable. Ecological production process. Solution Valmet DNA automation system controls the operation of the entire plant. Easy operation, transparency in control algorithms. Remote operation via control room of CHP plant Results Effectiveness of the controls has been visibly enhanced, especially plant s complex water balance control. Higher automation level Full auto run-up / shut down & purge sequences Optimized operation point of turbine 7
Why EWB selected the Valmet DNA system Valmet DNA offers a unified system with scalable architecture, high availability, lifetime expandability and upgradeability. 8 Valmet
Everything goes automatic in Valmet DNA Before: start/stop of the turbine was not full automatic gate control did not support different variations in automatic Now: full automatic turbine start / stop More freedom for operators gate control supports different variations or priorities in automatic 11
Everything in high resolution on video Before: no history mode, no high resolution alarm list Now: full trend, event archive and reporting for all values and alarms seamless connection to office (excel, pdf) high resolution alarm list Benefit for customer EWB: Better data analyses search functions & data access to history data faster & more efficient fault analysis 12
Water balance control Valmet DNA WBC
Maximum power - in balance with environment Maximum flow through turbine 100m 3 /s Pond water level to be kept at fixed level (+/-5cm) Residual minimum water flow 10-12m 3 /s, through 500kW turbine 1 st priority: pond level, flooding emergency 3rd priority: head water emergency level 2 nd priority: Residual flow, compliance with environmental regulations 4 th priority: power plant max. power production 15
Customer decided pro high available solution Before retrofit: Complicated redundancy for water balance control After retrofit: Functional & geographical redundancy of the Valmet DNA WBC water balance control HW redundancy of WBC at dam Functional redundancy HW redundancy of WBC at HPP 16 Benefit: Higher availability of automatic mode higher availability of full functionality Transparent control loops (no black box) Easy parameter changes
Valmet DNA turbine controller offers new trim options
Valmet DNA turbine controller features Implemented standard features : Speed or frequency control Load or flow control Start / stop sequences Purge programs No black box Fault diagnostic Main operator display Additionally customer got: Same HW & engineering tools as plant DCS Main sequence display 19
Valmet DNA turbine controller - Optimization Correlation wicket gate/ runner blades Monitoring of actual correlation wicket gate / runner blades angle Runner blades follow wicket gate acc. these curves Different operating curves, dependent on pond level (head) Actual operation point Optimization wicket gate/ runner blades Correlation adjustment to increase the efficiency Limitation of opening of wicket gate Limitation of max. opening of wicket gate e.g. for safety reasons (cavitation, acceleration > 250% / min.) Efficiency (optimum operation point in low./max. flow range) 21
Valmet DNA vibration monitoring & mechanical protection
Felsenau vibration monitoring system Integrated application in Valmet DNA system Same HW & engineering tools as plant DCS 4 Eddy probes Monitoring of unbalance, eccentricity, resonance, orbit TÜV approved mechanical protection acc. SIL 3 Operator interface fully integrated for fast analysis Turbine graphic display Turbine protection logic
Valmet DNA Training simulators
Valmet DNA Power plant training simulator HPP Simulator to simulate operation, trending and reporting functions to avoid malfunctions to understand the plant technology operator training for new staff realistic simulation same HW as in HPP training in a safe environment skilled operators for more efficiency better environmental aspects less downtime less equipment wear Direct access from HPP Felsenau overview display Power plant simulator same look & feel 26 Valmet
Valmet DNA River simulator River Simulator wave simulation upstream HPP Matte flood (e.g. heavy weather conditions) simulation of levels upstream and pond how to react in the power plant max. additional capacity through the turbine max. displacement through the river Wave simulation configuration HPP Matte Simulator control Ausgangslage Szenario Ganglinie OWP engehalde Q null Q Turb Q GA Q engehalde 1 Ganglinie 1 495,54 m.ü.m 140,00 m³/s 100,00 m³/s 0,00 m³/s 40,00 m³/s 2 Ganglinie 2 495,54 m.ü.m 120,00 m³/s 80,00 m³/s 0,00 m³/s 40,00 m³/s 3 Ganglinie 3 495,54 m.ü.m 320,00 m³/s 100,00 m³/s 0,00 m³/s 220,00 m³/s 4 Ganglinie 4 495,54 m.ü.m 260,00 m³/s 100,00 m³/s 0,00 m³/s 160,00 m³/s 5 Ganglinie 4 495,54 m.ü.m 260,00 m³/s 0,00 m³/s 60,00 m³/s 200,00 m³/s 6 Ganglinie 5 495,54 m.ü.m 80,00 m³/s 68,00 m³/s 0,00 m³/s 12,00 m³/s 7 Ganglinie 5 495,44 m.ü.m 80,00 m³/s 0,00 m³/s 0,00 m³/s 80,00 m³/s 8 Ganglinie 6 495,44 m.ü.m 160,00 m³/s 0,00 m³/s 0,00 m³/s 160,00 m³/s 9 Ganglinie 7 495,54 m.ü.m 196,00 m³/s 0,00 m³/s 60,00 m³/s 136,00 m³/s 27 Valmet
Valmet DNA Operate the window to the plant
Valmet DNA Operate - intuitive & straightforward Customer feels the easiness of use Functions developed for production professionals Graphical navigation Relevant information brought to the foreground Select object to get related information Point and click, drag and drop principle Combines process information and organisation s discussions in a single tool What happened during last shift or last weekend? Time machine gives the answer! 29 Valmet
Interlocking signals and functional descriptions The interlockings page displays the state of the loop and any interlocking connections to other loops. From interlockings can also found loop that triggered the first interlocking ( ). Tells how the loop works & shows the interlocking information Integrated to operator interface Benefits Problem solving & faster start up s Learning 31 Valmet
Valmet DNA Information Management Applications
Valmet DNA Information Activity Server IAS is a functional extension to the operator stations provides a better process overview independent databases for continuous process values & events long time data archiving for years incl. data compression measurement interval adjustable per measured value from 1s up simple analysis of disturbances supply of data for reports and analysis in Excel simple distribution of reports and trends to office with WEB-Explorer 34
Valmet DNA Report - reporting & analyzing tools Web based tool for EWB management low maintenance costs no installations available throughout the enterprise control room and office automatic export to other formats e.g. pdf, xls Dynamic and adaptive Use all data sources in Valmet DNA Historian Change time, production and process settings online and regenerate the report Standard solutions for regulatory reporting EEMUA, SPC and OEE Tailored reports using drag and drop tools
Valmet DNA Disturbance Management High resolution post-mortem trend triggering Monitoring machine start-ups / stops / disturbances Registration of fast events & trends (min. resolution 10ms) Comments can be added Disturbance report over time period Disturbance Post Mortem Trend 37 Title/Author Date <<
Valmet DNA Operate efficient problem solving Time machine feature for any picture For collected tags History replay from any picture in time-laps mode Drag n Drop to analysis tools Switch to history mode History mode indication Select time in history and replay 38 Valmet
Enhanced effectiveness of the controls The control is now fully automated and all the information is easily and quickly available. The events and context are much more visible. 39
Improved operational effectiveness Our expectations for the new system have been exceeded by far. The system is in operation since June 2014 without any disturbances. I am glad that we selected your system. Andres Wäfler Manager of Power Plants & Contracting at Energie Wasser Bern 40
42 Raising automation level at a Swiss HPP