Han MK, Business Development (Power Generation), 23rd March 2010 ABB Power and Automation Days ABB in Power Generation Content ABB Power Generation ABB Solutions for Power Generation ABB Solutions for Water Lifecycle ABB ICE Solution Energy Efficiency and Reliability Solutions System Integration and Service March 31, 2010 Slide 2
ABB Activities in Power Generation Fossil-Fired Steam & gas turbines Diesel Wind Solar Hydro Co-generation Waste-to-Energy Desalination March 31, 2010 Slide 3 ABB delivers and energies up to 25% of a power plant Integration of Instrumentation, Control & Electrical Sys INSTRUMENTATION Temperature Pressure Flow Level ANALYZERS ACTUATOR ON-OFF, Controlled LV SWITCHGEAR MV MOTORS LV MOTORS March 31, 2010 Slide 4 Markets served Utilities, industries, OEMs, EPCs, distributors
Introducing iice solutions from ABB integrating all of your plant systems and equipment! Instrumentation Field instruments, analyzers, control valves & actuators Control Systems Automation systems for controlling the plant, monitoring performance & equipment, and protecting & maintaining the assets in the plant Integration Integrative Systems Engineering services for power, electrical and control systems resulting in highest plant availibility and best energy efficiency iice Electrical Systems A full portfolio of electrical products, systems and engineering services: Motor Control Centers LV / MV / HV Switchgear Generator Circuit Breakers Excitation & Synchronization LV / MV Voltage Drives Transformers & Substations UPS & Emergency Systems Fire & Security Systems Lighting & Comms Systems Cabling and Connections Modular Solutions March 31, 2010 Slide 5 Customer s Benefits No coordination for partner scope Optimized economical and technical application Improved and guaranteed power availability and power quality Greater flexibility and reduced operating costs Reduce execution, technical and commercial risk Robust and reliable ABB products and systems ABB solutions for the water lifecycle Complete turnkey provider March 31, 2010 Slide 6
Control System Trends in Power Plant Automation DCS Platform Process Automation Substation Automation common communication standards Modbus Industrial Ethernet common communication standards IEC 61850 IEC 60870-5 -101/-104-103 LON SPA Sensors, Actuators, Low Voltage (LV) Low Voltage Switchgear Medium Voltage Motors & Drives Medium Voltage Switchgear Unit Protection With the new power plant generation and introduction of IEC 61850 the requirements for substation automation and process control will merge March 31, 2010 Slide 7 Extended Automation System 800xA MES and Business Systems Office workplace remote access Remote Operator and Engineering Clients WLAN Extended Operator Workplace ECS, ISA-95, OPC Router / Firewall PGIM / Optimax Servers Enterprise LAN System Servers Maintenance Operation Operation Engineering Ethernet Control Network Process Electrification LV & MV - Switchgears - Smart MCC s - Frequency converters - Multi-drive Power Plant Automation Local Panels Turbine Controls & Protection Turbine Protection Valve Positioning Safety Modbus, OPC.. 3rd party System Power Distribution Power Management - Network control & protection - Load Shedding Process Instrumentation Auto Sync Machinery Condition Monitoring - Boiler Protection - Burner Management March 31, 2010 Slide 8 TCP/IP IEC61850
Energy efficiency and reliability solutions Reducing losses along the energy chain ABB technology helping at every step Primary energy Transport Generation T&D Industrial processes Industrial production Available energy Improved well efficiency Higher pipeline flows More efficient fuel combustion Lower line losses, higher substation efficiency ABB technology can double energy productivity Improved productivity More efficient motors & drives Process Automation Marine & pipelines Power plant automation Grid operation Process automation Drives & motors March 31, 2010 Slide 10
Variable Speed Drives for various types of power generation Gas turbine power plants Steam generating boilers, waste incinerators District heating, Combined Heat and Power Fuel handling Selective Catalytic Reduction, Flue Gas Desulphurization Clean coal and CO 2 capture Pumped storage hydro power plants Renewable energy Nuclear power plants GT starters, drives for fuel gas booster compressors, boiler (HRSG) feed-water pumps and cooling water pumps Drives for boiler feed-water, cooling water and circulation water pumps, FD and ID fans Drives for water circulation pumps in industrial and municipal Combined Heat and Power (CHP) plants Drives for conveyors and coal mills Drives for ID booster fans, limestone slurry feed and absorbent circulation pumps and oxidation air compressors Drives and soft starters for syngas, air and CO 2 compressors Soft starters for hydro turbines Drives for geothermal power plants and soft starters for synchronous condensers Drives for feed-water, condensate recirculation and cooling-water pumps March 31, 2010 Slide 11 Variable Speed Drives for power generation applications Benefits High availability Fast and precise process control under all conditions Minimized energy consumption Reduced CO 2 emissions Minimized actuator equipment Soft starting features for a longer lifetime of electrical and mechanical equipment Reduced maintenance costs March 31, 2010 Slide 12 Pumps Boiler feed-water pump Condensate extraction pump Cooling water pump District heating circulation pump Limestone slurry feed and absorbent circulation pump Fans Primary air fan Secondary air fan ID fan ID booster fan Other Conveyor Coal mill Oxidation air compressor Gas turbine starter Fuel gas booster compressor
Power Generation optimization solutions OPTIMAX Operations Maintenance OPTIMAX Environmental Information Management Asset Lifecycle How do you identify deviations and introduce corrective action early? How can you improve efficiency and operate closer to design limits? Can you extend the life of critical equipment and increase the utilization of existing assets? What can you improve in your maintenance workflow? Which factors influence your reliability and availability? Plant Optimization solutions, and Information Management, improve economic performance and availability! March 31, 2010 Slide 13 OPTIMAX plant optimization solutions Improve economic performance and asset management The ABB Integration Experts Creating an environment of optimized and efficient operations by combining innovative products, power generation specific solutions and the latest IT technology through the industry s most experience engineering staff Plant Optimization Systems including, plant management and asset management solutions specifically designed for Power Generation Operations Systems Monitor and predict plant performance, improve efficiency and issue early warnings for equipment diagnosis and preventive maintenance. Environmental Systems Optimize your combustion process and reduce emissions with Advanced Process Control solutions. Plant Automation Systems Field Devices, Instrumentation & Distributed Control Systems Plant Electrical Systems Electrical Equipment / Products used in Balance of Plant applications Asset Lifecycle Systems Schedule the most economical operation of different units (unit commitment) and improve maintenance planning based on lifetime consumption. Maintenance Systems Reduce costs of maintenance activities and improve maintenance work flow. March 31, 2010 Slide 14
OPTIMAX plant optimization solutions - portfolio March 31, 2010 Slide 15 OPTIMAX plant optimization solutions Typical layout Office Engineering Maintenance Accounting OPTIMAX Client OPTIMAX Client OPTIMAX Client OPTIMAX Client Internet Firewall Fuel Demand Process Quality Balances Reporting Monitoring Diagnostics Simulation Optimization System Server Billing & Settlement Information Mgmt Calculation Server Maintenance Mgmt DCS Interfaces Metering System Unit 1 ABB DCS 1 Unit 2 ABB DCS 2 Unit Other DCS March 31, 2010 Slide 16
Power Generation Increase of reliability throught Plant Retrofit ABB focuses on stepwise programs to upgrade existing systems and equipment, integrating traditional and new system and control components to provide operational improvement. ABB has the expertise required for developing and delivering measurable results through tailored up-grade paths for installed systems and products. March 31, 2010 Slide 17 Solutions for Life-Extension Enhanced functionalities by upgrading to the latest system version Protecting customers financial and intellectual investment by migration of outdated systems while re-using existing engineering data and still usable hardware Flexible concepts for step-wise or full-scale retrofit by replacing outdated equipment (if necessary) Extension of plant life through rehabilitation/retrofit of the complete system March 31, 2010 Slide 18
Energy audit To reduce energy costs, a company should evaluate its energy usage An energy audit is a systematic examination of applications It includes monitoring of energy consumed before and after the change ABB offers energy audits that rapidly determine where and how much energy can be saved Assessment of the existing operating and control strategies Determination of the optimum operating modes and schedules for various operating conditions and demand situations Assessment of process variability and disturbances Identification of the operational and process constraints preventing the plant running closer to the optimum (such as capacity limits, limitations in the rate of boiler and turbine load changes, etc.) Evaluation of coordinated control strategies for the plant components, in particular for process upset conditions Determination of instrumentation and data communication needs Determination of Variable Speed Drive needs and applications Determination of High efficiency motors needs and applications March 31, 2010 Slide 19 System integration and service
Power Generation System Integration and Service System integration Project development support Basic engineering and consulting Engineering and procurement Erection and commissioning Life cycle management Service and maintenance Upgrade and migration Life cycle extension Feasibility studies and optimization March 31, 2010 Slide 21