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Excellence in plant control

HyCon Control System

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 Control room in
Omkareshwar, India

HyCon Control
System
Voith Hydro is one of the global leaders in hydropower from a single source to ensure complete service and to ensure
plant equipment and services for both new and modern- seamless availability for your hydropower plant and all of its
ization projects. components and systems.

Our reputation for excellence in products and services is Our automation solutions are based on a variety of subsys-
based on reliability, trust and commitment in long-lasting, tems that ensure a safe, reliable and cost-effective operation
partnering relationships with owners and operators around the through our long-term process know-how and control system
world. expertise in hydropower applications.

This applies to overall plant engineering as well as to single From these systems, the control system is the central inter-
component and system design in electrical and hydraulic face between the operator and the hydropower generation
machines, including the entire range of hydropower plant process. Our HyCon Control Systems offer perfect solutions
control concepts and systems. We offer hydro automation for safe and reliable hydropower control.

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The HyCon Control System family is tailor-made to meet
the specific requirements of each hydropower plant. It thus
provides second to none reliability, functionality and safety.

Proven technology meets highest quality HyCon is an uniform solution with seamless integration of all
and reliability standards systems.
Voith offers its portfolio of automation solutions under the
name HyCon, characterized by highest quality and reliable Tailor-made solutions
approved technology, in order to fulfill all demands in terms of The HyCon object library with functions tailored to the hydro
control and supervision, in line with market and customer ne- process deliver plenty of advantages including:
cessities of delivering a sustainable solution in the long term. • Flexibility for project specific modifications

• Slim and modern design

Seamless integration • Voith Hydro ownership

Today integration and smart handling of assets is becoming • Direct support up to third level

more and more important. Integration of all digital and me-

chanical systems within the hydropower plant into one control Voith guarantees and ensures an outstandingly high and
philosophy is a must. Within the HyCon family all subsystems constant quality level for all projects due to our centralized
are fully integrated into the control system. This includes not intensive system- and integration tests for all supported con-
only turbine governor and either voltage regulator or excita- figurations.
tion, but also electrical and mechanical protection. This is an
invaluable advantage for our customers with regard to main-
tenance and spare part management.

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Flexible and scalable solution
for any hydropower plant

The Voith Hydro HyCon Control System is offering

complete and comprehensive SCADA functionality
for all power plant environments.

• The main advantage of HyCon solution is the full flexibility

Voith guarantees in the engineering tool, and is prepared
to fulfill all requirements of hydropower controls.
• The HyCon solution is also using the hydro specific library
of objects and therefore are fitting perfectly to hydro
applications.
• HyCon solution is scalable over a wide range of
applications, from single station to distributed systems
with different levels of redundancy.

Herdecke, Germany

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HyCon Control System
The intelligent choice

Investment protection Reliable operation

Voith wants to ensure the maximum benefit from your HyCon The proven operation philosophy applied in HyCon systems
Control System installation. As there is a discrepancy between has been successfully implemented in hydropower plants of
the life cycle of the power unit an the control system and all types and sizes all over the world. A cornerstone of this
an even more significant discrepancy between the lifetime of concept is the fully object-oriented hydro block library using
the PLC and the operator stations respectively the servers of state-of-the-art faceplate technology for the operator station’s
the control system, Voith is investing into clear strategies to displays.
protect your investments. To handle these discrepancies in a
technically feasible and economically intelligent way we offer This technology and other features, like the sophisticated
a clear migration and upgrade strategy to keep your control sequence representation with special monitoring functions,
system efficiently up-to-date. This helps you to protect your make sure that the operator always has the overview on
investments. the status of the process even in difficult situations requiring
special attention. Another feature to make the process trans-
To support this strategy Voith is offering a wide range of parent to the operator is the advanced fault tracking capabili-
services tailored for HyCon Control Systems like: ties via picture tree and loop-in alarm.
• Spare parts handling and supply

• Modification of system functionality

• Telephone hotline support

• Service contracts

• Remote diagnosis support through OnPerformance.Lab

• Regular maintenance of the equipment on site: e. g.

– Back-ups, check of all alarms, etc.

– Start-up support after unit overhaul

Control room in Gigel Gibe, Ethopia

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Built-in plant safety
The HyCon Control System family features
The control system provides reliable operation and is a key
factor for plant safety. Our hydro block library is designed to • IT / OT security included, for examples firewalls and
meet the high level of safety standards embedded in all Voith anti-malware tools
hydro products to guarantee an optimum of safety for the • Flexible remote access solutions
user, the capital equipment, and the environment. • Web interface
• Messaging system support, for example pager and SMS
The mechanical protection is implemented in PLC (Program- • Control room equipment
mable Logic Controller) technology. A sophisticated trip matrix • Hierarchically structured access control
concept allows high flexibility to define finely graduated re- • Parameter access and change without engineering tool
sponses to any abnormal events in mechanical subsystems. • Ergonomic screen design based on international
standards like IEC 60073 and others
IT / OT security • Multiple language support (online switchable)
For all components of HyCon Control Systems measures are • Hard and software diagnosis in the PLC controller
taken to safeguard protection from cyber attacks and system • Powerful trend and archiving system
hardening. This includes that all functions not necessarily re- • Central engineering tool with one central database
quired for the operation of the system are deactivated or de- • Historian functionality
leted (e. g. USB ports). Functions accessible over the network • Multi screen
are reduced to a minimum and are individually adapted to the • Multi server
project specific needs. Thus the relevant international stan- • Multi clients
dards (like ISO / IEC 27002, ISO / IEC 27019, IEC 62351, NERC
CIP-007-4) are met by our HyCon Control System family.

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Pump turbine overview Braking system

Drainage and dewatering Turbine guide bearing

Hydraulic governor Unit switch gear

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HyCon Control System
Selected highlights

Sequences – Plant operation Open communication

The sequences build the brain of the control process of the Open communication standards are an absolute must for a
hydropower plant operation. With the help of the sequences modern power plant control system. HyCon supports a wide
the power units are started, stopped and operated. Here not range of open interfaces including IEC 60870-5-101 / 103 / 104
only the technological know-how of Voith to operate hydro- and IEC 61850. The Profibus DP / Profinet is the solution to
power units is required but also the best-in-class programming communicate to decentralized I / Os, the most widely used
to ensure safe and reliable operation in all operating modes. field bus systems with more than 28 million installations world-
wide. Voith is delivering highest quality. This includes certifica-
• The documentation and definition of the sequences is tion for open communication standards to allow you a seam-
done in one step, this avoids mismatches less integration of our solutions into your existing environment.
• The definition of the sequences is done graphically The IEC protocol implementations provided by Voith have
• There is an enhanced display of the transitions according been certified by KEMA / TÜV Süd.
to the parameterization
• Signal information within the sequences is shown as Built-in flexibility
plain text and signal status Even though HyCon automation products are designed to
• In case of a failure the signal states are stored for later provide an integrated overall automation system, all compo-
on diagnostics nents may be used as stand-alone systems as well. HyCon
Control Systems have been delivered for all types of hydraulic
Event matrix machines and generators. Due to the flexible concepts and
• Any signal can be integrated in the event matrix the process expertise of Voith, the systems can be used for
• Up to 32 responses can be defined (freely configurable new plants as well as for modernization projects. HyCon Con-
without programming) trol Systems can be perfectly matched for any existing power
• In case of an event the causing signal and the response plant in the world. It is our mission to have a solution for any
is highlighted challenge in hydropower automation. Several add-on function-
• The causing signal is stored and must be reset manually alities can easily be integrated into HyCon Control System
helping you to optimize the plant output.
Independent local operation
State-of-the-art control systems ensure high reliability of Joint control
the central control system level especially if the servers are The HyCon JC – Joint Control is an integral part of the HyCon
provided as a redundant solution. However, the capability for Control System library. It allows you to distribute the active
local operation, for example at the unit control cabinet, which and reactive power to all units within the power plant. The
is completely independent of the central server, is a real added calculation of the optimal unit configuration is based on effi-
value in each hydropower plant, for example for commission- ciency curves stored and processed in the PLC. This allows
ing, recommissioning after maintenance work and in emer- easy and safe operation of the complete plant. There are sev-
gency cases. All HyCon Control Systems provide independent eral additional features included like definition of a spinning
local operation using operation panels or panel PCs. reserve as a constraint. In mixed mode not all units must be
assigned to the Joint Control (however units in manual mode
are considered in total power balancing).

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Operation
The Voith control system family is always pursuing one goal: We can ensure this by several options:
We want to provide a comprehensive operation functionality
for reliable control of the hydropower plant process. We reach Intelligent limiting of active alarms
this goal by providing an intuitive and flexible navigation for • Removes “non-relevant” alarms

fast information access, e. g. you can jump from group alarm • Filters “nuisance” alarms

display straight to graphical representation and therefore have • Suppresses alarms without defined “operator reaction“

all information available on one click.

Alarm prioritization
Intelligent alarm management • Important alarms are always shown in the alarm line first

An intelligent alarm management helps to keep cool when • A warning of the generator is more important than an alarm

there are unforeseen events. Our intelligent alarm management from another plant item
delivers the right alarms to the right person at the right time.

Control system – SCADA setup common section Joint controller overview

General overview Main inlet valve

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HyCon Control Systems
Hardware structure
Mobile Client
Industrial
Wireless LAN

Video Wall
OS Single Station / Redundant OnCare.Health Hydro OS Client
Station

Industrial Ethernet,
Terminal Bus, Single / Redundant

…OS Server…

Industrial Ethernet, Plant Bus,

Single / Redundant / IEC61850 /
IEC60870-5-104

A.S Fault-Tolerant

S7-400H /
HyCon Controller HMI HMI
Client / DELPHIN Single Station
Single Station
OnCare.Health Hydro
ET 200M / SOE
1 ms Scalance ET 200M

1 ms (SOE) 1 ms (SOE)
Profibus DP

Y-Link Profinet
Y-Link
OLM

PAC3000 PAC3000

Thyricon Thyricon
(Voith Excitation) (Voith Excitation)
HyCon GC HyCon GC
S7-1500 HMI TP (Voith Governor) S7-1500 HMI TP (Voith Governor)
Temperature Temperature
OLM Monitoring Monitoring

Scalance ET 200M

IO-Link
ET 200M

IO-Link

DELPHIN IEC60870-
OnCare.Health Hydro 5-104
S7-1500

HMI TP

Ethernet
S7-1500

Modbus
AS-I
Others

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 Communication: Web Client
Intranet, Internet
Ethernet, Office LAN

WAN

WAN Voith Remote

Support
Firewall

Web Archive Server Engineering Open PCS7 / OS

Server Single / Redundant Station Client
Network IEC60870-5-104
printer IEC60870-5-101
Modbus RTU
DNP3
OPC
Others

GPS GPS
Satellite

S7-400 / HyCon Communication

HyCon Controller Controller

Protection
Profibus DP

HMI TP Protective Relay

OLM

ET 200M / SOE 1 ms IEC60870-5-104

IEC60870-5-101
DISPATCH
Profibus DP

IEC 61850

DNP3
CENTER
Profinet

IEC 61850
PAC3000

ET 200M

ET 200M

IO-Link
DELPHIN
OnCare.Health Hydro

Thyricon
(Voith Excitation)
S7-1500 HMI TP HyCon GC
Scalance (Voith Governor)
ET 200M Temperature
Monitoring

IEC60870-
5-104
S7-1500

Thyricon
HMI TP (Voith Excitation)
HyCon GC
(Voith Governor)
Ethernet
S7-1500 Temperature
Monitoring
Modbus
AS-I
Others

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High-end solution
to satisfy all your needs

HyCon is designed to fulfill ambitious requirements such as

Major features in detail
the automation of pumped storage plants with very challeng-
ing demands regarding safety, reliability and stabilization of • Scalable redundancy (hot stand-by) for PLCs,
the grid. These are features which are especially crucial for network, server.
power plants contributing to the primary control of the grid. • Distributed server configurations for multi-unit plants,
very complex auxiliaries and others.
The HyCon control system is designed to cover a consider- • Transparent user guidance and intuitive operation
able range of requirements. For this purpose, HyCon is using faceplate technology.
extremely scalable and – due to the modular design – the • Ergonomically designed process screens which help
system can grow with the demands. Starting from a cost- to focus the user attention to what is most relevant.
effective all-in-one concept up to distributed architectures • Local operation completely independent of the central
and redundancy in all levels of the system, HyCon is prepared server using the same screens and faceplates like in
to meet all your requirements. the central control room. Local server functionality
provided if central server or communication fails.
Furthermore, a broad spectrum of standard interfaces allows • Powerful and highly flexible representation of step
the integration of existing components into the control system sequences (optionally branched) including special
– this is especially valuable for modernization projects. monitoring functions for failure analysis. This concept
is designed in particular to handle complex transitions
Redundancy concepts for pump-turbines monitoring functions for failure
To increase the availability of the control system several re- analysis. This concept is designed in particular to
dundancy concepts are available, such as PLC redundancy, handle complex transitions for pump-turbines.
OS redundancy and network redundancy. • Scalable archiving system with separate archive server
as an option.
• Flexible reporting tool based on MS Excel.
• Central time synchronization server (GPS, NTP
synchronization).
• Alarm and messaging system supporting efficient
disturbance analysis and fault tracking.
• SOE for all messages like alarms and events.
• Clear and transparent concepts for administration
of user rights, interlocking of control locations and
integrated alarm acknowledgement that is effective
system wide.

Control room in Inga,

Democratic Republic
of the Congo

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 1 2

4 5

References in recent years

2013 Sedrun, Switzerland 2015 Ingula, South Africa
3 x 26 MW, Pelton units 4 x 342 MW, Pump-turbine units

2013 Karcham Wangtoo, India 2015 La Muela II, Spain

3 x 280 MW, Francis units 4 x 213 MW, Pump-turbine units

2013 Alfalfal II (Alto Maipo), Chile 2015 Cambambe II, Angola

2 x 135.6 MW, Pelton units 4 x 180 MW, Francis units

2013 Churchill Falls, Canada 2015 Alecrin, Brazil

11 x 494 MW, Francis units 2 x 2 MW, Francis units

2014 Budarhals, Iceland 2016 Coo, Belgium

2 x 40 MW, Kaplan units 3 x 145 MW, 3 x 200 MW Pump-turbine units

2014 Bagliar II, India 2016 Smithland, United States

3 x 150 MW, Francis units 3 x 25 MW, Kaplan units

2014 Belo Monte, Brazil 2016 Willow Island, United States

18 x 620 MW, Francis units 2 x 21 MW, Kaplan units

2014 Barra-Votorantin, Brazil 2016 Achwa Ugande

3 x 1 MW, Francis units 3 x 10 MW, Francis units

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 1 Budarhals
2 Frades II
3 Ingula
4 Smithland
5 Inga
6 La Muela

2017 Frades II, Portugal

2 x 380 MW, VarSpeed Pump-turbine units

2017 Baglihar I, India

3 x 150 MW, Francis units

2017 Mount Coffee, Liberia

4 x 22 MW, Francis units

2017 Dakpsi 2B, Vietnam

2 x 7 MW, Francis units

2018 Cannelton, United States

3 x 29 MW, Kaplan units

2018 Inga I, Congo

6 x 60 MW, Francis units

2018 Semangka, India

2 x 29 MW, Francis units

2018 Alin B1, Vietnam

2 x 23 MW, Francis units

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 VH3354, en, vvk, 2021-10. All data and information without obligation. Subject to change.

Voith Group
Voith Hydro Holding GmbH & Co. KG
Alexanderstr. 11
89522 Heidenheim, Germany

Contact:
Phone +49 7321 37-9990
[email protected]
www.voith.com/digitalhydro