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Plant Management

Power Plant Management

Power Plant Management

Your Target

For single power plants as well as for power plant cascades, power production has to be maximised whereas the costs have to be reduced to
a minimum.

Modern power plant management systems have to fulfil these tasks in a very efficient way. Beside the plant's operational requirements (e.g.
maintenance cycle) the system has to take into account a number of external regulations (water management, contracts, environmental
regulations).

Production planning requires different modules for forecasting and optimisation. Information has to be provided to other applications (e.g.
commercial and administrative software tools) via standard interfaces.

All these different requirements require a modular overall concept.

Besides its main task - maximising of energy production - the system has to support the operators in all different operating conditions (e.g.
normal operation, flood and disturbances). At the same time the system has to contribute to the reduction of operation and maintenance
costs.

On the basis of the existing infrastructure, an easy integration into the power plant's environment must be possible.

The Common Solution

Typical Tasks:

Power Plant Control

 head water level control

 discharge control
 power control
 reactive power control
Authority and Environmental Regulations

 downstream water flow limitation

 filling and discharging gradients
 level limitations
 flood alert

Forecast

 meteorological data (precipitation, temperature, snow depth, ...)

 calculation of incoming water quantities

Optimisation

 energy production
 reservoir utilisation
 swell operation of
 power plant cascades
 production scheduling

Interfaces

 equipment and maintenance

 database systems
 commercial database systems
 geographical information systems
 office packages

Marketing and Sales

 Internet (promotion)
 Intranet

Our Products

 SICAM 1703
The SICAM 1703 Automation&Control system forms the platform for controlling of the power Generation process. State-of-the-art
32-Bit multi-processor technology is the powerful basis of centralised as well as decentralised control concepts. Optimised
redundancy solutions assure highest availability of important process functions.

 CAEx plus
CAEx plus is a graphical PLC programming user interface, according to IEC 61131-3. CAEX plus is characterised by easy operation
and user-friendliness.

 SAT 1000
The SAT 1000 product family is the basis of the safe communication. It interconnects all relevant components inside and outside of
the plant. By usage of Ethernet technology, seamless connection to the Internet/Intranet is possible, allowing to implement new,
powerful and cost-effective solutions.

 SAT 250 SCALA

The SAT 250 SCALA product family represents a full-featured modern SCADA-system for hydro power plants. By its modular
design, it allows to integrate functions as prognosis, production scheduling, ....

 SICAM TOOLBOX II
The SAT TOOLBOX II product family provides most modern software tools for data management, system engineering and
comprehensive system diagnosis, supporting the engineering and service staff.

 Software Application
By consequent usage of international standards for system interfaces, various software applications (e.g. standard office packages
or customer specific software) can be easily integrated.

 ASC 2005
The Andritz Station Control system 2005 is responsible for fully automatic, unmanned operation of the power station and dam,
under the requirement for maximum energy generation and safety.

Process features:
   - Headwater level control with optimization of the control behaviour, lowest strain on actuators
  - Maximum energy gereration
  - Power house - barrage discharge distribution
  - First step synchronous and last step logics for barrage
  - Automatic starting and stopping of the machine sets
  - Process signal recording
  - Operator panel
  - Alarm messaging and logging
  - Industrial suitability  

Hardware features:
  - Modular, upgradable hardware (local and remote peripheral equipment)
  - High-performance CPU with FlashPROM
  - Flexible network interfaces
  - Industrial suitability, high availability
  - Ease of handling

Software features:
  - Multitasking operating system with selectable task times
  - Graphic programming interface
  - Extensive, process-optimized function library
  - High-level language programming
  - Process data interfaces (DLL, DDE, OPC, WEB)
  - Automatically generated "as-built-documentation"
  - Remote access for engineering, debugging and operation (LAN, WAN, modem)
  - Grafic programming interface

Monitoring

Monitoring and Diagnosis

Easy Prevention of Damages

Nowadays power stations have to maximise production and minimise costs significantly. Even under normal operating conditions all
components (turbine, shaft, bearings, generator etc.) are subject to ageing and damages.

Advanced Monitoring and Diagnosis Systems have to look at leading indicators of condition changes, analyse the trend and have to provide
warnings if alarm levels are exceeded.

They should support in diagnosing the cause of deviations (abnormal ageing and failures) before serious damages occur.

The analytic and diagnostic results should assist the responsible persons (plant operators, technical specialists, plant owner's etc.) in making
decisions.

Thereby maintenance costs should be reduced and efficiency of power generation should be increased. The hardware and software used
should be based on up-to-date system concepts open to future developments or supplements.

Easy integration of existing monitoring components and customer specific extensions should be supported.

The Common Solution

Practical Examples:

 DIA TECH - Cooling Air - Hot Spot

Due to the early detection of the Hot Spot of a soldered joint, the downtime could be reduced to a minimum of two days for repair
(in case of unforeseen damage the repair time would be a maximum of 48 days). In this way outage time (outage cost) is reduced
from 48 days down to two days.

 DIA TECH - Structure Borne Sound

By means of the analysed structure borne sound loosening of stator core could be detected early. The trend observation over a
certain period indicated just a small increase of loosening there fore it was not necessary to react promptly, so the customer had
enough time to make a planned repair on the Generator - thereby at lower cost.

Our Products

 DIA TECH
DIA TECH was a joint development together with international Electric Generating Utilities. The implemented software and
hardware is based on advanced technologies (e.g. Windows®NT). Its modular system structure makes it possible to implement
enhancements or supplements developed by customers. The open system architecture guarantees easy integration of third party
products. Various diagnosis modules ("Knowledge Modules") are identifying mechanical, dielectrical and thermal problems.
Different operation modes (standstill, start up, steady state, shut down), and regimes (power generation, synchronous condenser
operation, pumping operation).

 Konwledge-Modules
    - Mechanical
    (stator winding, core, shaft, bearings, turbine)

   - Thermal
      (stator winding, core, soldered joints, bearings, cooling system)

  - Dielectrical
      (stator winding, condition of insulation surface)

Protection Systems and Devices

Safety By Protection

Electric machinery, such as generators, transformers, auxiliary systems, bus bars, overhead lines and cable feeders, etc. have to be provided
with protective features which will respond to internal and external faults and/or overloads or inadvertent false control operations to limit
damages to a minimum by selective and co-ordinated isolation of the respective electrical plant portion thereby ensuring continuity of supply
and safe operation for the remaining power system.

The properties of the electrical plant and the kind of applied equipment as well as the operating experience of the Power Authority and
economic considerations for new constructed equipment will eventually determine the selection of the electrical protection system.
Also during modernising and refurbishment of existing plant flexible devices and systems capable of providing an optimal technical and
economic solution have to be applied.

By use of versatile devices the spare part requirements can also be reduced to a minimum.

Besides the main tasks of a protective scheme, i.e. protective functions, modern protection systems will offer a series of additional functions
such as extensive self-monitoring, fault- and event records, remote communication with control systems, etc. The self-monitoring feature
provides a continuous availability check of the protective scheme and by analysis of the fault records an efficient and detailed clarification of
the fault event sequence can be made.

Operation of the devices is facilitated via modern graphic User software which is providing a sense of "Look and Feel" and a clear optical
display. False parameter settings are to a large extent prevented by the User program.

               

             

» HYDRO » Automation » Protection » DRS-LIGHT

 Protection System - DRS-LIGHT

This protection relay with the smallest dimensions is preferably employed for small plants, e.g.generators, transformers, etc. but also for
feeders, bus bars and back-up functions. With the local User interface it provides comfortable service operation and has the same system
features as the higher relay system DRS-COMPACT.

The available relay models are cost-efficiently configured for various applications. The device is easily commissioned and therefore also very
suitable for industrial use.

Protection System - DRS-COMPACT2

The compact protection relay is applicable for medium-sized and large plants and due to the local key pad operation and LED display is
providing a very comfortable User operation. For typical applications there are standardised relay models, i.e. a combination of protective
functions and hardware features.

The modern software structure also enables customer specific function configurations which can cater for specific plant requirements or
desired back-up functionality in a most economic way.

The compact mechanical construction enables simple installation and speedy commissioning.
 Protection System - DRS-LLD

The digital line differential relay DRS-LLD is a protective device for overhead lines and power cables. Up to 6 line ends can be covered by the
scheme. Also a transformer can be included in the protected area.

The hard- and software represent a new and extended version of the well tried DRS-BB bus bar protection. The design is based on our more
than 40-year experience in the power plant protection division.
 Protection System - DRS-BB

The de-centralised low impedance numeric bus bar protection enables a flexible application for almost all possible bus layouts due to the
inherent universal concept.

A redundant fibre optic high-speed interface bus guaranties tripping times of 15ms typical. The same User comfort as for other products of
the DRS-family provides the local operation and configuration of the Field Units and the Central Unit via the User interface, as by all other
DRS relays, and also operation from remote control locations.
Synchronising Systems

Synchronising generators to the system or paralleling transmission lines and power systems is a particular critical case. In former times you
needed a calm hand and full concentration, which increased the heart rate. Nowadays you can, thanks to the modern and mature technology,
settle this relaxed and automated. You calmly can watch how the pointers move on the screen and you only hear a soft synchronisation
procedure in the powerhouse. All values are recorded for easy analyses in the office.

Safety

If you synchronise, everything shall go perfectly! What would you have done in case of zero beat in former times? Or where you able to
measure the CB closing time during each maintenance? Claims, which only can come true with an intelligent, redundant and hard tested
technology. Our synchronising systems combine your high claim for reliability with our experience for more than 40 years in this sector.

Comfort

What is your vision? Easy learning screen visualisation, measuring of circuit breaker (CB) closing time, recording of curves, LAN-ability with
Ethernet protocol to other technological systems, operation on PC/notebook and locally on device? Do you also want to leave behind the HEX-
tables, operation manuals, laborious calibration and trying? Therefore we make it as easy as possible for you!
Turbine Controller

Flexible Turbine Control   Download

State-of-the-art turbine controllers must meet the highest demands concerning safety, economy
  NEPTUN-Turbine
 ger - engl
Controller
 
and availability. The basic requirements are a hardware platform suitable for industrial application
and the use of international standards. Most modern, graphical user interfaces should allow for
  Data Sheet TC 1703 Digital
Turbine Control System  
simple operation of the turbine controller. In addition, efficient remote parameterisation and
diagnostic functions should be available for quick and simple maintenance and service access.
  Data Sheet SM 1703 Speed
Monitoring  
Operational safety must be guaranteed even under the most difficult ambient conditions (e.g.
moisture, EMC). Also the sensor technology for picking up the process signals must be designed to
  Data Sheet TC 1703 XL Digital
Turbine Control System  
meet the highest requirements. Particularly the sensors for speed and servo motor position should
be drift-free and thus be maintenance-free. The mechanical design should be optimised towards
  Brochure
2005
Turbine Controller ATC
 
minimum space requirements.

The Common Solution

Since both the controller hardware and the standardised controller algorithm are modular, the
application can individually be adjusted to the requirements of the power plant. After a functional
test of the controller in the workshop, erection and commissioning is carried out by experienced
specialist engineers. First priority is given to the safety of the plant at any time. Comprehensive
services, spare part guarantees and training classes complete our scope of delivery.

Our Products

 TC 1703
The modular TC 1703 offers all advantages of a modern, scalable turbine controller for
the use as an individual unit, but also as an integrated part within the power plant
automation system. Powerful 32-Bit microprocessor technology, integrated diagnostic
functions and various configuration concepts assure highest availability. The modular
system design allows centralised and decentralised interfacing to the peripheral signals.
Efficient communication concepts allow for a simple integration into the existing plant.
For quick hardware exchange, a modern plug-and-play concept is available.

 CAEx plus
CAEx plus is a graphical engineering tool acc. to IEC 61131-3, which stands out for its
 simple operation and user-friendly programming.

 Reglerapplikation
The turbine controller TC 1703 can be universally used for all turbines. lt can make use
of standard PID schemes, advanced control algorithms with adaptable parameter setting
values or state based control algorithms.

Operation Modes
  - Speed control
  - Power control
  - Discharge control
  - Water level control
Integrated Control Functions
  - Surge control
  - Adaptive Cam Control (ACC module)
  - Flow Calculation (FCA module)
  - Surge tank Protection Module (SPM module)
  - and others

Due to the possibility of integrating unit protection as well as start/stop sequencing, TC 1703 can
also be used as a complete compact control system.

 ATC 2005
State-of-the-art automation & control systems assist a simple and safe operation of a
hydro powerplant (units and dam gate) by the means of a three level strategy with local
control, control room access and remote control.

Process features:
  - Motor control center (MCC)
  - Uninterruptible power system (UPS)
  - DC distribution
  - Lighting distribution board
  - Auxiliary plant control for automatic and manual operation
  - Unit starting and stop sequence
  - Switch over logic for grid and isolated network
  - Alarm messaging and logging
  - Industrial network structure
  - Industrial suitability
  - Process monitoring and visualisation (HMI / SCADA)
  - Local and central control room operation

Hardware features:
  - Modular, upgradable hardware (local and remote peripheral equipment)
  - High-performance CPU with FlashPROM
  - Flexible network interfaces
  - Industrial suitability, high availability
  - Ease of handling

Software features:
  - Multitasking operating system with selectable task times
  - Graphic programming interface
  - Extensive, process-optimized function library
  - High-level language programming
  - Process data interfaces (DLL, DDE, OPC, WEB)
  - Automatically generated "as-built-documentation"
  - Remote access for engineering, debugging and operation (LAN, WAN, modem)
  - Grafic programming interface

Strategy

CORPORATE STRATEGY

International technology Group ANDRITZ ranks among the global market leaders in all five of its business areas. One of the
Group’s overall strategic goals is to consolidate and extend this position, and, at the same time, secure profitable long-term
growth.

WORLD MARKET LEADERSHIP

The ANDRITZ GROUP is a globally leading supplier of plants and services for the hydropower, pulp and paper, metals, and other specialized
industries (solid/liquid separation, feed and biofuel) and has the goal to become the world market leader in all of the markets it serves.

 Focus on growth markets

All five ANDRITZ business areas serve markets with long-term and sustained growth potential. Within these markets, the Group
focuses on rapidly growing segments, e.g. renewable energy sources (hydropower and biomass), stainless steel, or special paper
grades (tissue). ANDRITZ’s long-term goal is to generate more than 50% of its sales from products related to renewable energies.

 Global presence
ANDRITZ serves globally acting companies all over the world. In order to meet customers’ needs as best and as quickly as
possible, ANDRITZ has a global presence with over 120 locations (including production facilities, service and sales companies). The
Group’s goal is to further strengthen local service presence close to its customers.

 Research and development

ANDRITZ is among the technological leaders in all five of its business areas and invests heavily in research and development. On
average, approximately 3% of sales are invested in research and development every year, and over 300 employees work in the
Group’s research centers. The main goal is to develop customized technologies that enhance productivity of customer’s plants,
minimize operating costs, and maximize energy efficiency and environmental protection.

 Complementary acquisitions
ANDRITZ continues to look out for opportunities to acquire companies and businesses that complement its existing range of
products, process technologies, and services. The goal is to be a single-source supplier with full-line capabilities in all business
areas.

PROFITABLE GROWTH

All strategic measures are focused on maintaining profitable growth in the long-term. With this in mind, ANDRITZ is pursuing three overall
strategic goals:

 Increasing sales by an average of 10% per annum, based on organic expansion, mainly by research and development, as well as
acquisitions. In the past decade, sales of the Group have increased by approximately 15% per annum.

 Achieving profitability (EBITA margin) of 7% on average over the cycle. In the past ten years, the average EBITA margin has
seen a steady increase. Whereas the EBITA margin average was 5.3% from 2000 to 2004, this figure increased to 6.3% (excl.
restructuring expenses) from 2005 to 2009.

 Extending the service portfolio in order to help customers achieve their goals in terms of productivity, profitability, and
sustainability.