P13 news

2 I 13 The ABB Procontrol® P13 news bulletin

Welcome to the new issue of the Procontrol P13 news bulletin Dear Readers, I’m pleased to bring you our second Procontrol P13 news, intended for users of the ABB Procontrol P13 control system. I trust you enjoyed our first issue, and would like to thank you for all of the positive feedback and requests we have received. This issue focuses on our life cycle service program for Procontrol P13 systems. We present two project stories highlighting successful upgrades that have extended the lifetime and performance of P13 systems. We consider essential topics, such as: − increased hardware reliability − updated software to increase functionality and secure use of the latest computer hardware for operation and engineering

− new functionality that reduces cumbersome processes and increases the flow of information, creating flexibility for fast action − ensuring proven upgrade procedures are available within very short shutdown times In addition to the upgrade projects, there is an article about service and maintenance, demonstrating the strong ABB “backbone” of customer support in essential areas like repair, spare part management, life cycle management and more. ABB can help you secure reliable operation beyond the traditional lifetime of control products.

I hope you find the information and insights valuable, and consider the support services described for your own operations. As always, we look forward to your feedback and invite you to share your interests and comments with us. And we are always happy to provide any additional information or advice you may need.

I wish you happy reading. Kind regards Matthias Bolliger VP, Head of Global Execution ABB Power Systems

Projects

Projects

Be “in touch” with your control system ABB control systems provide unique solutions for all customer requirements, including the need for “hands-on” operational capability. This case study demonstrates how easily the Procontrol P13 control system can be augmented with the latest HMI and IT technologies. The Rumford Paper Company owns a paper mill in Maine, USA, which can produce 100 percent of its energy (process steam and electricity) using multiple boilers and a 120 MVA steam turbine generator controlled by ABB’s Procontrol P13 distributed control system (DCS). The control application is based on ABB’s Turboturn control solution for industrial steam turbines, consisting of 3 local buses with four processing modules. The P13 DCS has worked reliably since the day it was installed, but even the most durable systems need maintenance from time to time. In addition, upgrading the old HMI system with a third party solution a few years back did not produce the expected benefits, so the customer asked ABB about maintenance possibilities for the entire system. To ensure safe, reliable operation now and well into the future, ABB proposed a full scope of P13 on-site upgrade and maintenance services over the course of

two years, which commenced in 2012. First, the existing engineering tools were upgraded to Progress 3, ABB’s latest Windows-based engineering and diagnostic solution. Progress 3 is a programming, documentation and service tool specifically designed to upgrade or replace older generation Procontrol engineering tools, enhancing the ability of plant operators to completely maintain the plant control system with all options in fault-finding, trip analysis and even preventive maintenance. In addition, critical electronic components like wet capacitors and fuses were refurbished in all operating modules and spares in stock to prevent premature card failures, and avoid plant unavailability. This year, the work concluded with the replacement of the outdated 3rd party HMI with ABB’s latest HMI solution, which includes the tailor-made Procontrol P13 connectivity package based on the P13 OPC server. The new HMI is

Main control room operation panels with integrated touch screens at Rumford Paper Mill.

connected redundantly to the P13 system via the reliable and widely-used ModBus protocol and newly installed 70BK06a modules. In planning the HMI upgrade, ABB took care to ensure every customer requirement was fully met. Pre-existing functionality has been freshly implemented according to customer specifications. A unique feature of this solution are two touch screen operator workplaces that

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have been directly integrated into the main control room operation panels. Problems with the old hardware meant the touch screen workplaces did not work anymore. ABB’s flexible HMI solution put these workplaces back in service again, upgraded to the latest touch screen technology.

delivering a solution. ABB’s highly skilled and experienced engineering team kept the schedule with no delays. Commissioning was finished in just two days during a scheduled outage with no additional downtime, ensuring minimal loss of production for the customer.

A particular challenge of the HMI upgrade was the tight schedule – just eight weeks from receiving the purchase order to The ABB Procontrol® P13 news bulletin 2 | 13

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Projects

Projects

ABB control system upgrade improves hydro plant reliability in India Procontrol P13 with a current HMI solution averts total control system replacement. The Sardar Sarovar hydropower plant on the Narmada River near Navagam, Gujarat is one of India’s largest water resource projects, covering the major states of Maharashtra, Madhya Pradesh, Gujarat and Rajasthan. With a total installed generation capacity of 1,450 MW, Sardar Sarovar provides other benefits to the region, including irrigation, drinking water and flood protection. 250 MW of the total capacity are generated with five Kaplan turbines located in the Canal Head Power House. In 2010, ABB won an order to upgrade the control system for five of the power plant’s generating units located in the Canal Head Power House. Each unit consists of a Kaplan turbine with 50 MW and uses an ABB Procontrol P13 / 42 control system “that had been installed in the early 90s through BHEL.” Upgrades included five stations for autosequence of the individual units, one common station each for auxiliary control and switch yard monitoring, and a diagnostics station, all connected through an P13 / 42 intra-plant bus. This was necessary, because the old HMI system (POSE) was not functional anymore, which made it difficult to monitor and operate the plant. Synchronization was done manually. For local operations of breakers, isolators and bus couplers, operation engineers had to walk nearly 300 mt to the switchyard area, as the remote P13 station envisaged for this was not in operation since the original commissioning. ABB engineers conducted a detailed survey of the plant and held detailed discussions with the customer to thoroughly analyze and find solutions to these problems. This helped convince 4

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The canal head power house of the Sardar Sarovar dam with the five Kaplan turbines.

the customer that improving the control system’s reliability and availability could be achieved by small parts upgrades using ABB components and solutions, rather than totally replacing the control system as the customer had planned. Among the many successful upgrades, ABB implemented a new HMI system for the auto sequencer function (single HMI command for startup and shutdown) that operates through the existing P13 system; auto-synchronization with a synchronizing panel common to all five units; and a new engineering / diagnostic station supported by the Progress 3 engineering tool. The upgraded system now provides an overview of plant engineering, modification and maintenance, a remote view only system, a revived intra-plant bus, a functional switchyard and station auxiliary monitoring and operations system, training for maintenance and operation engineers, improved documentation and a supply of critical spare parts. The project was completed in July 2011, and the numerous customer benefits

include a single integrated platform for plant operations, providing a single window from plant startup to auto-sequencing and auto-synchronizing to grid. Operation of the plant via HMI is possible for the first time, and Progress 3 with its capability of online monitoring of the functional logicis a substantial enhancement of the P13 control system’s diagnostic features. Auto-synchronizing all units using ABB’s Synchrotact5 was a huge value addition for smooth plant operation. This optimized upgrade solution for ABB’s Procontrol P13 system has increased control system reliability, eased plant operations, increased plant availability, improved diagnostics and fault finding features, improved online monitoring and simulation, provided trouble-free synchronization, remote status updates, and remote monitoring / operation of station auxiliaries and switchyard with a stateof-the-art HMI. In addition ABB has also provided the plant with an annual maintenance contract for continuous system services. The ABB Procontrol® P13 news bulletin 2 | 13

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Service

Service

P13 Service & Maintenance ABB’s strategy for spare part management Last year the service manager of Limmat Kraftwerke AG, a small power plant operator in Switzerland, asked ABB to review their P13 spare part strategy. ABB analyzed the complete P13 module inventory, including modules in operation and storage. Based on this analysis and the age of the modules, ABB developed a custom spare part strategy and rec application profile. The customer accepted these recommendations, and now has a control system that is ready to meet power demand well into the future.

Do you know the condition of your spare part inventory? ABB can help minimize avoidable costs resulting from inadequate spare part management, including: − In an emergency, unexpected costs due to plant outage caused by missing spare parts − Obsolete and incompatible spare parts that have been held too long − Unreliable application and uncertain operability resulting from inadequate parts storage − Misplaced spare parts due to reorganizations and fluctuations in personnel The first step is to contact ABB Service for an evaluation of your current active and stored inventory. Based on this analysis, ABB can recommend tailored services to improve your spare part strategy.

ABB is committed to maintaining Procontrol P13’s high level of quality at all times. For more than 30 years the platform has been developed, manufactured and repaired in Baden, Switzerland, providing safe and reliable power plant operation all over the world. In addition, the global execution center for Procontrol P13 maintains an extensive service and support center for P13 controls. Service engineers with years of experience in Procontrol P13 backed up by modern test facilities support local business units and our customers with troubleshooting, repairs and plant extensions of Procontrol P13.

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The Procontrol P13 service offering covers the lifetime needs of your power plant: Spare parts As the OEM for P13, ABB can provide a comprehensive selection of quality, Swissmade spare parts that come with a manufacturer guarantee. Fitting and preventive maintenance Refurbishing your active and stored P13 modules by replacing life-time critical parts ensures continued reliable operation of your plant long into the future. Repairs In a worst case scenario and if economically justified, ABB will repair and test your P13 modules at the original production facilities. Upgrades Many first and second generation P13 modules have been improved with a

new hardware revision, or replaced by a compatible successor. ABB can create a tailor-made upgrade strategy that provides access to the latest generation P13 modules, based on your application profile.

Service & Support Contacts Spare Parts & Repairs Vivien Simor Phone: +41 58 585 69 90 Email: [email protected]

Support & Hotline Phone: +41 58 585 88 80 (Office Hours) +41 844 845 845 (24h Support line) Email: [email protected]

Shipping Information (Repairs & Returns) ABB Switzerland Ltd. Power Systems / PSPGS Attn: Vivien Simor Bruggerstrasse 72 5400 Baden Switzerland

P13 Webshop Our tool for online spare part quotes and direct orders: www.abb.com/powergeneration Control Procontrol P13 Procontrol P13 Online Store

Spare parts inventory management Depending on your resources and P13 knowledge, ABB will gladly help you define an optimum spare part management strategy (see below). Support & Hotline In case of emergencies or urgently needed help, ABB provides a tailored support and service agreement, which includes a 24h support line accessible by phone and e-mail (see right). On-Site Service For critical maintenance tasks and during upgrades, ABB P13 specialists will visit your site to ensure optimum execution.

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Contact

Contact

Procontrol P13 presence worldwide We are here to support you P13 Global Execution Center ABB Switzerland – Power Systems Matthias Bolliger Bruggerstrasse 72 CH-5400 Baden, Switzerland Phone: +41 (0)844 845 845 Email: [email protected]

ABB China: YaoDong Han Phone: +86 10 64233649 E-mail: [email protected]

ABB UK: Anton Joseph Phone: +44 7885 333 831 E-mail: [email protected] ABB Canada: Steve J Chomyc Phone: +1 905 333 7467 E-mail: [email protected]

ABB South Korea: Jong-Sig Park Phone: +8225283181 E-mail: [email protected]

ABB Poland: Dariusz Ferenc Phone: +48 71 347 56 92 E-mail: [email protected]

ABB USA: Please contact your account manager or Tom Maczuzak Phone: +1 440 585 6862 E-mail: [email protected]

ABB Thailand: Tanin Plamin Phone: +6626651000 1290 E-mail: [email protected]

ABB Switzerland: Matthias Bolliger Phone: +41 58 586 85 75 E-mail: [email protected]

ABB Taiwan: Jenny Gong Phone: +886287516090395 E-mail: [email protected] ABB Philippines: Oscar Cabrera Phone: +6328217777 514 E-mail: [email protected]

ABB Spain: Frank Van-Dreumel Phone: +34915819361 E-mail: [email protected] ABB Mexico: Alejandro Hernandez Phone: +52 55 3601 9666 E-mail: [email protected]

ABB Peru: Julio Regalado Phone: +5114155100 1403 E-mail: [email protected]

ABB Brasilia: Adriano Pires Phone: +55 1124644854 E-mail: [email protected]

ABB Argentina: Daniel Guerrero Phone: +54 11 4229 5500 E-mail: [email protected]

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ABB Malaysia: Kuang-Meng Yang Phone: +60356284567 E-mail: [email protected]

ABB United Arab Emirates: Prakash Mysore Phone: +971 2 4938382 E-mail: [email protected]

ABB Bahrain: Rajeev Padmanabhan Phone: +97317810647 E-mail: [email protected]

ABB Saudi Arabia: Syed Akhtar Phone: +966 1 2653030 E-mail: [email protected]

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ABB Vietnam: Ngoc LeMinh Phone: +84438611010 260 E-mail: [email protected]

ABB India: Sudipta A Saha Phone: +918022949628 E-mail: [email protected]

ABB South Africa: Johann Wasserman Phone: +27 10 202 6007 E-mail: [email protected]

ABB Indonesia: Yulius Christiady Phone: +62816837228 E-mail: [email protected] ABB Singapore: Ikshvakoo Vaid Phone: +65 6773 8240 E-mail: [email protected]

ABB Australia: Andrew Joyce Phone: +61 3 8577 7369 E-mail: [email protected]

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www.abb.com/powergeneration

Procontrol® P13 Product Portal: www.abb.com/industries/us/9AAC30301251.aspx

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Notice The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product meets the requirements specified in EMC Directive 89 / 336 / EEC and in Low Voltage Directive 72 / 2.

© Copyright ABB Switzerland Ltd

ABB Switzerland Ltd Power Systems Bruggerstrasse 72 CH-5400 Baden, Switzerland Phone: +41 (0)844 845 845 (customer contact center 24 hours / 365 days) Phone: +41 (0)58 585 88 80 (during office hours) Email: [email protected]

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