Solutions for steam and combined cycle

power plants
2 Solutions for steam and combined cycle power plants
Single source provider with worldwide
presence

ABB a life cycle partner Your needs our response: ABB as single source provider
We support our customers through all stages of a plants life with worldwide presence
cycle, from project development through operations to life We are creating an environment of optimized and efficient
extension. Our advanced life cycle services help to generate operations by combining innovative products, sector-specific
extra value from installed assets by maximizing availability solutions and the latest technology with the industrys most
and performance. ABB is the ideal partner for utilities, general experienced engineering experts. We offer the leading port-
contractors, plant suppliers, and process equipment sup- folio of solutions and services for the power generation
pliers. industry. Our global footprint comprises of sales offices,
service centers and manufacturing facilities in more than
High efficiency, low emissions 100 countries, providing our customers power plants with
The huge demand for new power plant capacities can only world-class electrical and automation systems.
be met by high efficiency coal, oil and gas fired power plants.
New technologies have been developed increasing the ef- Advantages of ABB`s turn key solutions
ficiencies of steam power plants to more than 44% with the Modern power plants rely on sophisticated instrumentation,
long-term target of crossing the 50% limit in converting fuel control and electrical systems, all working in harmony. Dedi-
into electricity. Efficient advanced control of the plant must be cated scientists and innovative engineers ensure that power
adopted to meet these targets. Modern fossil power plants systems operate flawlessly, delivering reliable power. Experts
meet emission rules by applying optimized combustion tech- not only contribute their specialized knowledge in the field of
nologies and employing sophisticated flue gas cleaning lines. instrumentation, control and electrical engineering, but also
In this respect the instrumentation, automation and electrical draw on their extensive knowledge of power plant processes.
systems also play an important role in meeting the targets Plant automation systems combine innovative and broad
required by authorities for emissions. functionality with proven operational reliability.
The advantages of ABB full scope solutions are:
easy cooperation
cost effectiveness
short delivery time
high quality
one partner throughout the plant lifecycle
longstanding experience, many references
Our ability to execute complex projects has been proven in
more than 270 combined cycle power plant and 750 steam
power plant installations world-wide.

Solutions for steam and combined cycle power plants 3

 Electrical Balance of Plant
ABB has the engineering expertise, experience and state-of-
the-art technology to deliver turnkey system integration of
electrical Balance of Plant (eBoP) applications. We offer com-
plete engineering, procurement, installation, commissioning
and testing as well as ensure the quality of the eBoP integra-

Integration of tion with the complete plant automation system of your power
facility. Direct control over all engineering and project manage-

instrumentation, ment functions enables us to build and maintain reliable power

system installations safely and efficiently, offering cost effective
solutions.
control and Grid connections

electrical systems ABB provides the complete portfolio to connect a power plant
to the grid. This includes the bus ducts to connect the gene-
rator, the generator circuit breaker, the power transformer and
the complete high voltage substation including all protection
and control facilities.

Electrical plant auxiliaries

ABB provides medium and low voltage systems consisting of
transformers, switchgear, frequency converters and motors.
For reliable back-up power ABB can integrate diesel engines
and uninterruptible power supply systems (UPS) that include
rectifier/battery charger, batteries, inverters, DC switchgear
and distribution.

4 Solutions for steam and combined cycle power plants

Electrical generator auxiliaries Years of experience in the field help ABB engineers design
ABB can provide generator auxiliary systems: excitation sys- control systems that cover all the plant requirements. One
tems, generator and unit protection, synchronization, measu- important feature of the plant automation system is total
ring and metering and static starter systems. As part of our integration of all the main functional areas of the plant into
excitation systems, we provide microprocessor based voltage one common system. The system incorporates a uniform
regulators for synchronous machines with rotating exciters operator interface throughout the plant. All data acquisition
and static excitation systems for high per-formance control of functions form an integral part of the system, including
synchronous machines. built-in sequence of events and extensive system diagnostics.

For gas turbines our static starter system softly accelerates The automation for gas and steam turbine plants can be
the generator up the ignition speed of the gas turbine. The implemented in one common platform with the following
system allows the same static frequency converter (SFC) to benefits:
be used for purging and slow turning during cool down of gas common look and feel in operations
turbines. seamless integration in hardware and software
common engineering and diagnostic tools
Variable speed drives reduced spare parts requirement
Variable speed drives increase plant availability and flexibility simplified maintenance and training
through improved process control. They are being considered
more and more often as an alternative to fixed speed motors Integration of process and substation automation
or controls by throttling valve or liquid coupling in feed water into one system
pumps, cooling water pumps, fire fighting pumps and fuel gas The requirement of higher operating efficiency in power gene-
booster compressors. ration nowadays is more and more in the spotlight. Traditional
control systems are confined to the vertical integration of
Miscellaneous equipment process control. It is quite common to use separate SCADA
ABB delivers additional solutions: systems for electrical systems. However, there exists an over-
grounding and lightning protection lap between these domains: major loads though belonging
lighting and power sockets to the process are operated by medium voltage switch gear.
telephone and communication systems Until now the necessary interconnection required the instal-
security and alarm systems lation of costly and inflexible marshalling racks. Integrated
clock systems, fire detection, CCTV operation and diagnostics was difficult to implement.

Plant automation systems ABBs state-of-the-art control systems connect these two
ABB delivers all the systems required to successfully automate worlds in one system by integration of substation automa-
a power plant: from the plant floor to the enterprise level, tion. They provide suitable workplaces for the electrical part
from system design to operation. Our automation platform, of the plant and therefore make specialized human-machine
instrumentation, valves and drives are designed for the most interfaces for electrical systems in power plants dispensable.
stringent requirements of power plant automation and are The use of the open standard IEC 61850 provides freedom
customized for steam and gas turbine power plants. of choice in equipment and full access to all substation data.
The very fact that only one system is needed adds up to a
ABBs control systems combine innovation and broad functio- more simple system architecture and hence reduced costs
nality with established operational reliability. Development of for purchase and maintenance.
our power plant control systems is ongoing, with the aim of
further improving cost-effectiveness, functionality and quality.
The advantages of these control solutions are:
future-oriented platform for process and electrical systems
easy-to-use and consistent user interface
fast analysis of disturbances
simple plant and enterprise-wide access to information
high engineering efficiency and quality
low operating and maintenance costs
simple system architecture
state-of-the-art technology including field buses and easy
integration methods of existing systems.

Solutions for steam and combined cycle power plants 5

Turbine and boiler control

Gas turbine control Steam turbine control

ABB can supply turbine control and monitoring solutions for Over the last 40 years, ABB has proven its expertise in au-
a full range of gas turbines, including heavy-duty machinery. tomation projects with most turbine OEMs. These solutions
Our turbine control solutions comprise the turbine governor, cover control, protection and turbine supervisory equipment.
sequence control, drive control and turbine protection. ABBs turbine control solutions are tightly integrated into the
Operation of the gas turbine can be fully automated; the plant automation system, ensuring advantageously seamless
various systems of the plant are automatically controlled in integration of operation, engineering and diagnostic functions.
a sequential manner. Minimal operator intervention is required The steam turbine protection system can be built as a fault-
to start a complete CCPP unit. The protection can be built as tolerant 2oo3 system and can include a SIL 3 certified over-
a fault-tolerant 2oo3 system and can include a SIL 3 certified speed protection system. ABB can supply turbine-specific
over-speed protection system. electro-hydraulic and hydraulic products and solutions as
well as design expertise and consulting for steam turbines.
To enable customers to determine the actual state of the ma- Our solutions incorporate universal products, and can be
chine, a supervision system monitoring turbine speed, vibra- integrated into nearly any type of mechanical system used
tions, temperatures and stresses generated can be installed. today.

6 Solutions for steam and combined cycle power plants

Hydraulic solutions ABB strictly complies with the mayor industry standards,
ABB can supply turbine-specific electro-hydraulic and hy- such as:
draulic products and solutions as well as design expertise US National Fire Protection Association (NFPA)
and consulting for gas and steam turbines. Our solutions German TRD/DIN
incorporate universal products and can be integrated into IEC 61508 safety levels SIL1-3
nearly any type of mechanical system used today. A safety
hydraulic controlled 2oo3 trip bloc meets the requirements As well as those of other governing agencies, including:
of SIL 3 according to EN 61508. Factory Mutual (FM)
Industrial Risk Insurers,
Boiler protection / burner management systems Underwriters Laboratories (UL) and
Meeting the highest possible standard of safety and reliability relevant governmental authorities.
are among the most important requirements in power plant
operation. The use of advanced boiler automation systems and the need
to comply with the modern safety standards often means that
Boiler protection and burner management systems are de- state-of-the-art flame scanners and detectors must be used.
dicated to ensuring boiler furnace safety and fuel shutdown. For this purpose ABB has developed specific products that
For the past 80 years, ABB has worked with customers and meet all modern day industry standards.
industry standards organizations to improve boiler safety,
particularly during the most hazardous operating phases of
start-up and low-load operation.

Solutions for steam and combined cycle power plants 7

Engineering and optimization

Integration engineering In operations, customers use OPTIMAX to monitor and pre-

Instrumentation, control and electrical projects for power dict plant performance; issue early warnings for equipment
plants are characterized by engineering processes that con- diagnosis, sensor validation and preventive maintenance;
cern many technical disciplines such as field instrumentation, and improve plant efficiency by reducing fuel consumption
cabling, control engineering and electrical components. The and resulting emissions. The advantages for maintenance
parties involved, e.g. general contractors, consortium partners include reduced downtime and maintenance costs as well
and suppliers, though with different functions, are working on as improved data access for daily inspections and outage
the same project at the same time, usually at different distri- planning. The huge demand for new power plant capacities
buted locations. The engineering process for such a project can be met by high efficiency coal, oil and gas fired power
can be a major challenge, since distributed and simultaneous plants. New technologies have been developed increasing
procedures need to be accurately coordinated and target the efficiency of combined cycle power plants toward 60%.
oriented. The engineering tools must be suitable for handling Efficient advanced control of the turbine and the plant must
a series of complex interfaces for exchanging data and be adopted to meet these targets.
documents, while assuring a steady revision process and
a high degree of consistency and completeness of the Modern combined cycle power plants meet emission rules by
documentation. applying optimized combustion technologies. In this respect
the instrumentation, control and electrical systems also play
With its Engineering Integration Platform EIP ABB applies a an important role in meeting the targets required by the emis-
consistent solution for the entire engineering process, ranging sion authorities.
from input management for the process data needed for detail
engineering, installation and commissioning to the compilation OPTIMAX adjusts the combustion process and reduces emis-
of a consistent plant-specific documentation. sions by monitoring flame quality, measuring coal flow and
carbon-in-ash content; and improves controls with advanced
Power plant optimization OPTIMAX process control solutions. In asset management we can sche-
Technological advances in the field of control and software dule the most economical operation of different generating
engineering have enabled innovative plant optimization units, balancing income from sales against emissions and sa-
solutions. OPTIMAX is a set of decision-support tools that ving customers money in both emissions and life-cycle costs.
continuously assess conditions in the plant and provides
root-cause fault analysis for situations affecting the plants
performance.

8 Solutions for steam and combined cycle power plants

Life cycle commitment

We support our customer base through global service con- ABB is committed to being the world leader in providing
tracts assisted by a strong localized service organization. total integrated automation solutions for power generation,
This organization offers advanced and efficient services allowing our customers to meet the complex automation
from a comprehensive and modular portfolio to provide challenges of today and tomorrow.
emergency remediation, preventive maintenance and re-
mote diagnostic services. Additionally, we help our customers
maintain their financial and intellectual investment in their
assets through training programs, consulting services and
comprehensive migration strategies for system upgrades
and retrofits.

Solutions for steam and combined cycle power plants 9

Recent references

Nuon Magnum Power Plant, Netherlands HuaNeng QinBei Power Plant, Henan Province, P.R.China
EPC contractor: Mitsubishi Heavy Industries Japan Customer: HeNan HuaNeng QinBei
Completion: 2011 Power Generation
Completion: 2008
Key figures
Fully integrated 1300 MW gasification combined-cycle plant Key figures
Switchgear housed in modular pre-fabricated units for easy 4x600MW coal fired supercritical units, clean coal power plant
site installation Same type of DCS to cover full functions of unit
380-kV GIS substation will be used to connect the plant Guardant that units would meet all performance criteria
to the grid

Walsum 10, Duisburg, Germany Ras Abu Fontas BII, Qatar

Enduser: STEAG Enduser: Qatar Electricity and Water Company
Customer: Hitachi Power Europe (EPC) Customer: GE
Completion: 2009 Completion: 2007

Key figures Key figures

750 MW clean coal power plant with high efficiency and CCPP with 550 MW electrical power and desalination of
low emissions 40 million gallons water/day
Complete electrical system (EBoP) Complete design, engineering, installation and commissioning
Process control system including boiler and turbine control of the electrical systems
process optimization

10 Solutions for steam and combined cycle power plants

Solutions for steam and combined cycle power plants 11
Contact us

ABB Ltd.

DEABB 1648 10 en printed in Germany (01.11)

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