Tobias Keller, Vice President Excitation Products & Technology, ATPE

ABB excitation and synchronization

A short introduction
ABB
3BHS335164 E01 Rev. E
© ABB Group
June 4, 2012 | Slide 1
 Introducing ABB ABB
ABB Switzerland Ltd ABB
Power Electronics
Excitation business
Product portfolio
UNITROL® UNITROL®
MEGATROL MEGATROL
SYNCHROTACT® SYNCHROTACT®
UNIREC UNIREC
Software Tools

© ABB Group
June 4, 2012 | Slide 2
 Introducing ABB
ABB

© ABB Group
June 4, 2012 | Slide 3
A global leader in power and automation technologies
Leading market positions in main businesses

135,000 employees in about 100 countries

$38 billion in revenue (2011)
Formed in 1988 merger of Swiss and
Swedish engineering companies
Predecessors founded in 1883 and 1891
Publicly owned company with head
office in Switzerland
100 13.5
2011 380
1988

1883 1891
ABB
© ABB Group
June 4, 2012 | Slide 4
Power and productivity for a better world
ABB’s vision
ABB

As one of the world’s leading engineering companies, we

help our customers to use electrical power efficiently, to
increase industrial productivity and to lower environmental
impact in a sustainable way.

© ABB Group
June 4, 2012 | Slide 5
 Merging power and automation technologies
makes electricity network more reliable, flexible,
secure and efficient. Smart grid benefits include:
Lower power consumption
Greater use of renewable energy
ABB’s broad offering in both power and
automation technologies positions it uniquely to
support this evolution
Transformation of grid to take place over several
decades

ABB

ABB
© ABB Group
June 4, 2012 | Slide 6
Innovation is key to ABB’s competitive advantage
Leadership built on consistent R&D investment
ABB

More than $1.3 billion invested annually in R&D*

7,500 scientists and engineers
Collaboration with 70 universities
MIT (US), Tsinghua (China), KTH Royal Institute of Technology (Sweden), Indian Institute of
Technology (New Delhi), ETH (Switzerland), Karlsruhe (Germany), AGH University of Science and
Technology (Poland)
13
7,500
70 , , ,
, , , AGH
© ABB Group
June 4, 2012 | Slide 7
 ABB Switzerland Ltd
ABB

© ABB Group
June 4, 2012 | Slide 8
ABB Switzerland Overview
ABB

Headquarters: Baden, Switzerland

Focus on
Overall solutions for utilities and industries
Power products
Automation products
Orders in 2011: CHF 3.36 billion
Revenues in 2011: CHF 3.57 billion
6,600 employees

2011 : 33.6
2011 : 35.7
6,600
ABB Switzerland Locations
ABB

Headquarters
1
2
Baden 12
3 I
4 5 6 II
Engineering/ 7
8
production location Lenzburg
11
/

1 Schaffhausen III
2 Klingnau/
Kleindoettingen
3 Turgi/Unter-
siggenthal
4 Birr
5 Baden/Daettwil IV
6 Wettingen
7 Zurich
8 Lenzburg
9 Molinazzo di
Monteggio 13
10 Quartino 10
11 Deitingen
12 Birsfelden V
9
13 Geneva

Regional sales office

Baden
II Zuzwil
III Bern
IV Lausanne
© ABB Group
June 4, 2012 | Slide 10 V Pregassona
 Power Electronics

© ABB Group
June 4, 2012 | Slide 11
Power Electronics and MV Drives
Business overview – Global Product Groups
Power Electronics Traction MV Drives
Excitation Systems
Power generation
Synchronous motors

High Power Rectifiers

Aluminum smelters
Chlorine electrolysis
DC arc furnaces BORDLINE ACS 1000 / 1000i
Traction DC substations Propulsion converters 0.3 – 5 MW
MV Power Converter Systems for trains and locomotives ACS 5000
17 Hz rail power converters BORDLINE 2 – 22 MW
AC excitation Auxiliary converters ACS 6000
MV STATCOM for onboard power supply 3 – 27 MW
BORDLINE MEGADRIVE-LCI
MV Power Converter Products Battery chargers 2 – 72 MW (or higher)
MV wind power converters
…

LV Power Converter Products Metals Mining&Minerals Oil & Gas

Active voltage conditioners
Battery and fuel cell converters
Marine frequency converters Power Marine Water

© ABB Group
June 4, 2012 | Slide 12
Power Electronics and MV Drives
Global footprint and key locations

PRU OEM Packs

MVD Service Hub
PRU Excitation
LEC Excitation PRU Rectifiers LCC Factory in PL
LEC Rectifiers PRU Power Conv. LEC Excitation
LEC Power Conv. PRU Traction Conv. JV Rectifiers
Sales MV Drives PRU MV Drives JV Traction Sales MV Drives
R&D MV Drives PRU Service Assbly. MV Drives
LCC Factory in MX Sales MV Drives
LEC Excitation
LEC Rectifiers
LEC Traction
Assbly. MV Drives
LEC Excitation
LEC Rectifiers Sales MV Drives
Sales MV Drives

LEC Excitation LEC Excitation

LEC Rectifiers LEC Rectifiers
Sales MV Drives Sales MV Drives

PRU PRU LV Power Cv.

© ABB Group
June 4, 2012 | Slide 13
LEC
JV
Power Electronics and MV Drives
Global center of competence (Switzerland)

ABB

ABB , Turgi

ABB Dättwil

ABB ,
Lenzburg

© ABB Group
June 4, 2012 | Slide 14
Power Electronics and MV Drives
Center of excellence
PE and MV Drives center in Turgi, Switzerland: ABB’s
center of excellence for power electronics and MV
drives
Single location with global responsibility
Research and Development
Sales and Marketing
Engineering and Project Management
Production
Service
Number of employees
Schaffhausen
Baden
900
Turgi
Daettwil
Birr
Zurich
:
Lenzburg

Berne

Lausanne

Geneva
Pregassona

© ABB Group
900
June 4, 2012 | Slide 15
 Excitation business

© ABB Group
June 4, 2012 | Slide 16
ABB Switzerland
Global Product Line Excitation Systems
ABB

Aija Mankkinen
Assistant: I. Schwammel

Bahman Kazemi Pierre Enstedt Sergio Nienartowicz

-
Bangalore
Hans-Jörg Herzog Tobias Keller Rudolf Wieser Michael Locher Ramesh K.

Marketing Communication Development & Support Sales Sales Service Electrical

LEC Support Product Management Electrical Engineering Operation Service Engineering

VAR Support Mechanical Engineering Mechanical

Engineering
Product Sales Project Management
Commissioning
Component Sales Factory

© ABB Group
June 4, 2012 | Slide 17
Global Product Line Excitation Systems
Excitation Products and Technology

Tobias Keller

Stephan Egli
Peter Moor

Development & Support Product Management

Valerijs Knazkins Tobias Keller

Georg Meier Rudolf Moeckli

Matthias Bächle Werner Zimmerli
Dietmar Ebner
Wolfgang Knapp
David Stutz
Patrick Vandekerckhove

© ABB Group
June 4, 2012 | Slide 18
 Product portfolio

© ABB Group
June 4, 2012 | Slide 19
Key solutions for power plants

HV system Control room

Step up
transformer LV switchgear

AC & DC
HV-breaker AUXILIARY
SYSTEMS Control systems

2 1
Aux. Protection
Transf.
Governor Generato
1 r 2
breaker Static starter
PT’s
&
CT’s
Synchronizing
SYNCHRONOUS Excitation system
TURBINE GENERATOR

Star Excitation
point cubicle transformer

© ABB Group
June 4, 2012 | Slide 20
Excitation systems and synchronizing equipment Brands

UNITROL®
Excitation systems

MEGATROL
Static frequency converter and
static excitation system in one package

SYNCHROTACT®
Synchronizing equipment

UNIREC
Main Generator Rectifier and Excitation
© ABB Group
June 4, 2012 | Slide 21
for on board DC-grid solutions
Excitation systems and synchronizing equipment
Production site (Turgi)

What ensures high quality and reliability of our products:

Professional skills of our workers
Collaboration with certified suppliers
All systems undergo 100% functional test before
leaving the factory
:

© ABB Group
June 4, 2012 | Slide 22
100%
References
Lungmen NPP / Taiwan

/ Customer: Mitsubishi Electric Corp.

End user: Taiwan Power Corporation
Machine data: 2 x 1,600 MVA
Manufacturer: Mitsubishi Electric
Excitation data: Ifn = 9,750 A / Ufpl = 1,392 V

:
:
: 2 x 1,600 MVA
New installation
Delivery year 2001 2001 :
One of the largest
SES worldwide : Ifn = 9,750 A / Ufpl = 1,392 V

© ABB Group
June 4, 2012 | Slide 23
References
Itaipu HPP / Brazil - Paraguay
/ –
Plant extension Customer: Itaipu Binacional
Delivery year 2003
2003
The largest HPP Machine data: 9 x 823 MVA / 50Hz,
worldwide

9 x 737 MVA / 60Hz

Manufacturer: AAP
Excitation data: Ifn = 4,824 A, Ufpl = 1,474 V / 60Hz;
Ifn = 3,945 A, Ufpl = 2,356 V

:
: 9 x 823 MVA / 50Hz,
9 x 737 MVA / 60Hz
:
: Ifn = 4,824 A, Ufpl = 1,474 V / 60Hz;
Ifn = 3,945 A, Ufpl = 2,356 V
© ABB Group
June 4, 2012 | Slide 24
References
Longtan HPP / China

/
Customer: GEARI
New installation
Delivery year 2005 2005
Machine data: 7 x 778 MVA
Manufacturer: HEC / DFEM
Excitation data: Ifn = 3,493 A / Ufpl = 1,173 V

:
: 7 x 778 MVA
: /
: Ifn = 3,493 A / Ufpl = 1,173 V

© ABB Group
June 4, 2012 | Slide 25
 References
Haiyang NPP / China
/
Customer: Harbin Electrical Machinery Co. Ltd
Machine data: 1,600 MVA
Manufacturer: Harbin Electrical Machinery Co. Ltd
Excitation data: Ifn = 10,169 A / Ufpl = 1,018 V

:
: 2X1,250MW
:
New installation
2011
Delivery year 2011
: Ifn = 9, 265 A / Ufpl = 1,020 V

© ABB Group
June 4, 2012 | Slide 26
 References
Sanmen NPP / China
/
Customer: Harbin Electrical Machinery Co. Ltd
Machine data: 2X1,250MW
Manufacturer: Harbin Electrical Machinery Co. Ltd
Excitation data: Ifn = 9, 265 A / Ufpl = 1,020 V

:
: 2X1,250MW

New installation
:
Delivery year 2011 2011
: Ifn = 9, 265 A / Ufpl = 1,020 V
(70%

© ABB Group
June 4, 2012 | Slide 27
 Excitation systems
UNITROL ®

UNITROL ®

© ABB Group
June 4, 2012 | Slide 28
UNITROL excitation systems
Automatic voltage regulator system duties

Provide variable DC current with short time overload

capability
Control generator terminal voltage with suitable accuracy
Ensure stable operation with network and / or other
machines

E Keep machine within permissible operating range

AVR
Contribute to transient stability subsequent to a fault
Communicate with the power plant control system

SES

© ABB Group
June 4, 2012 | Slide 29
UNITROL ®
UNITROL ® 1000 / UNITROL ® 6000

© ABB Group
June 4, 2012 | Slide 30
 Excitation systems
®
UNITROL 1000

UNITROL ® 1000

© ABB Group
June 4, 2012 | Slide 31
UNITROL 1000 product family
until end of 2011
UNITROL ® 1000
2011

UNITROL 1000-15 UNITROL 1000-PM40 UNITROL 1000-7

Power module

© ABB Group
June 4, 2012 | Slide 32
UNITROL 1000 product family
from February 2012
UNITROL ® 1000
2012 2

UNITROL 1010
UNITROL 1020
UNITROL 1000-PM40
(power module)

© ABB Group
June 4, 2012 | Slide 33
UNITROL 1000 product family UNITROL ® 1000
Hardware overview
*) Ie > 15 A requires
UNITROL 1010 UNITROL 1020
external capacitor

Excitation current at 55 10 A cont. 20 A cont. *

°C 20 A ceiling 38 A ceiling
55 °C
Aux power supply YES YES

Panel NO YES
8 digital I/Os 8 digital I/Os
4 digital input 4 digital input
I/Os I/O 3 analog inputs 3 analog inputs
2 analog outputs 2 analog outputs

USB USB
RS485 RS485
Interfaces Ethernet Ethernet
(CAN) (CAN)

IP20 IP20
Mechanicals Low module height
Mounted inside generator
Mounted inside generator
© ABB Group
June 4, 2012 | Slide 34
 Excitation systems
®
UNITROL 6000
Product line

®
UNITROL 6000

© ABB Group
June 4, 2012 | Slide 35
UNITROL 6000 excitation systems UN6000
UN6080 control and converter UN6080

Compact converter and control unit UN6080 AVR and SES

Single and redundant configuration

1)
1)

Channel #1 Channel#2

CCM6080

CCM6080
PIN6080

PIN6080
CIO #1
CIO #1
1)
SM/SG

Discharge Field
flashing
UNITROL 6080

© ABB Group
June 4, 2012 | Slide 36
UNITROL 6000 excitation systems UNITROL ® 6000
UN6080 AVR, 25-60A indirect excitation UN6080 AVR, 25-60A

Thermal power plant

43.75 MVA / 10.5 kV
AVR

43.75 MVA / 10.5 kV

AVR

© ABB Group
June 4, 2012 | Slide 37
UNITROL 6000 excitation systems
UN6080 prepared to meet customer requirements
UN6080
Aux.Li Aux.Li
Supply transfer
ne Hz
50/60 Batter ne Hz
50/60 Batter
y y

-Q71 -Q72 -Q71 -Q72

-K71 -K72 -K71 -K72

AC-field circuit
-T04 -T04 breaker
-F60 -Q80 -F63 -F60 -Q80 -F63

-T60 -T63 -T60 -T63

-Q03

-V80
-V80
Converter
Aux. Aux.
protection and
Power Power on-line
-Q10 -Q20 -Q30 -Q10 -Q20 -Q30
maintenance

-A10 -A20 -A30 -A10 -A20 -A30

CH 1 CH 2 BFCR CH 1 CH 2 BFCR

-Q12 -Q22 -Q32 -Q12 -Q22 -Q32 On-line

-R02 maintenance
-A02
S007
-Q02
-R08 - - -
R V T
MOV 02 02 02

DC-field circuit
breaker

© ABB Group
June 4, 2012 | Slide 38
UNITROL 6000 excitation systems UNITROL ® 6000
UN6080 single channel static excitation UN6080

Hydro power plant

7 MVA / 6.4 kV
SES

7 MVA / 6.4 kV
SES

© ABB Group
June 4, 2012 | Slide 39
 Excitation systems
®
UNITROL 6800 medium
to large SES

®
UNITROL 6800

© ABB Group
June 4, 2012 | Slide 40
UNITROL 6000 excitation systems UNITROL ®
UN6800 controller and power converter
UN6800

AC 800PEC controller AC 800PEC UN6800 SES Measurement signals

Parallel converter operation

Optical data link

Thyristor gate control

Backup
control &
protection Converter

Control
channel#1
Converter
Control control
channel #2

I/O device
IO Device
IO Device

SG

Discharge Field
flashing

© ABB Group
June 4, 2012 | Slide 41
UNITROL 6800 static excitation system
UNITROL ® 6800

© ABB Group
June 4, 2012 | Slide 42
UNITROL excitation systems UNITROL ®
UNITROL 6800 controller technology UNITROL ® 6800

Powerful ABB power electronics controller AC 800PEC

Graphical software development with Matlab/SIMULINK RTW
IEC 61131 engineering software, ABB Control Builder
400 MHz Power PC CPU (IBM)
64 bit IEEE floating point calculation
ABB AC 800PEC
Matlab/SIMULINK RTW
IEC 61131 ABB Control Builder
600 MHz Power PC CPU (IBM)
64 IEEE
© ABB Group
June 4, 2012 | Slide 43
 Excitation systems
UN6000 Summary

UN6000

© ABB Group
June 4, 2012 | Slide 44
UNITROL excitation systems product portfolio UNITROL ®
Comparison major characteristics UN6080 / 6800 UN6080 / 6800
UN6800 static excitation system (SES) UN6080 AVR and SES
UN6800 (SES) UN6080 AVR SES
Measurement signals Measurement signals

Optical data link Optical data link

Optional Thyristor gate control Thyristor gate control

to be used alternatively or both

1)
1)

Backup
control &
protection Converter#1
Channel #1 Channel#2 BFCR
Control

CCM6080

CCM6080

CCM6080
Channel#1

PIN6080

PIN6080

PIN6080
Converter
Control control
Channel # 2

2 I/O IO
device
Device
IO Device

CIO #1
CIO #1
1) Basic I/O
SG
SM Direct hard wired
SM/SG

Discharge Field
flashing Field
Discharge flashing
UNITROL 6800 UNITROL 6080

© ABB Group
June 4, 2012 | Slide 45
UNITROL excitation systems product portfolio UNITROL ®
Comparison major characteristics UN6080 / 6800 UN6080 / 6800
UN6800 static excitation system (SES) UN6080 AVR and SES
UN6800 (SES) UN6080 AVR SES
UN6800 UN6080
Single, double, triple redundant control Single, double, triple redundant control
Up to 8 converters in parallel operation 1 converter in operation
n-1, n-2 (hot standby) 1 or 2 redundant converters
1+1 (cold standby)
Independent controller and converter
redundancy Controller and converter operate as one unit
1,600 … 10,000 ADC 10 … 1,600 ADC

UN6800 UN6080

8 n-1, 1
n-2 ( ) 1 2
1+1 ( )

1,600 … 10,000 ADC 10 … 1,600 ADC

© ABB Group
June 4, 2012 | Slide 46
 Excitation systems
Power System Stabilizer

PSS

© ABB Group
June 4, 2012 | Slide 47
Power System Stabilizer (PSS) (PSS)
Available types

Acc. to IEEE Standard 412.5 – 2005

Type PSS 2B
Single band PSS with fixed parameters
New - acc. to IEEE Standard 412.5 – 2005
Type PSS 4B
Multiband (MB) PSS with three individually adjustable bands dedicated to the low,
intermediate and high frequency modes of oscillations
Adaptive PSS
Self-tuning parameters based on present loading of generator and actual network conditions
IEEE Standard 412.5 – 2005
PSS 2B

IEEE Standard 412.5 – 2005 PSS

PSS 4B
(MB) PSS

PSS
PSS
© ABB Group
June 4, 2012 | Slide 48
 Excitation systems
®
UNITROL operator
interface

UNITROL ®

© ABB Group
June 4, 2012 | Slide 49
UNITROL 6080/UNITROL 1020 UNITROL ® 6080/
Service Control Panel (SCP) UNITROL ® 1020 (SCP)

Local operation of excitation system

Actual values (eg, UG, If)

Alarms and events

Event recorder

Parameter values and settings(eg, Vo, Ta)

(eg, UG, If)

(eg, Vo, Ta)

© ABB Group
June 4, 2012 | Slide 50
UNITROL 6080 / 6800 UNITROL ® 6080 / 6800
Excitation Control Terminal (ECT) (ECT)
Benefits
W x D x H (mm)
483 x 355 x 90
W x D x H (mm)
483 x 355 x 90
Comprehensive data acquisition and
Weight 7.3 kg 7.3 kg
representation
Independent data storage
Simple and fast troubleshooting
Password protected access levels
Selectable languages

Features
Local and/or remote control terminal
Stand-alone industrial PC with 15" color
touch screen
/
15“ PC
© ABB Group
June 4, 2012 | Slide 51
UNITROL 6080 / 6800 UNITROL ® 6080 / 6800
Excitation Control Terminal (ECT) (ECT)

© ABB Group
June 4, 2012 | Slide 52
 MEGATROL
Package solution to start
gas turbines and excite
their generator
MEGATROL

© ABB Group
June 4, 2012 | Slide 53
 MEGATROL system interaction MEGATROL
SSD Output power SSD
GT torque
Excitation current
Speed

Actual state:

SSD ON
Ignition
Field weakening
SSD OFF
G
EXC ON
© ABB Group
June 4, 2012 | Slide 54 Synchronizing
MEGATROL product Line MEGATROL
Static excitation current, SSD starting power , SSD

Excitation Current IEN /A

© ABB Group
June 4, 2012 | Slide 55
MEGATROL Light MEGATROL
Arrangement

© ABB Group
June 4, 2012 | Slide 56
MEGATROL MEGATROL
Cross start

DCS #1 DCS #2 DCS #3 DCS #4 DCS #5 DCS #6

Unit #1

Unit #3

Unit #5
© ABB Group
June 4, 2012 | Slide 57
 Synchronizing equipment
SYNCHROTACT ®

SYNCHROTACT®

© ABB Group
June 4, 2012 | Slide 58
SYNCHROTACT synchronizing equipment
Generator synchronizing and paralleling of lines
SYNCHROTACT®

U1 SYNCHROTACT 5

CMD
CB
U2

AVR
U+
U-
G GV
f+
f- S 99003

© ABB Group
June 4, 2012 | Slide 59
SYNCHROTACT synchronizing equipment
Automatic synchronizer and synchrocheck
SYNCHROTACT ®
Synchrocheck
Automatic single channel synchronizing
device
Automatic dual channel synchronizing device
Redundant automatic dual channel
synchronizing device

© ABB Group
June 4, 2012 | Slide 60
SYNCHROTACT SYNCHROTACT ®
Advantages and benefits
Highest security against incorrect paralleling
Redundant design with two brands of digital signal processors each with its
own software architecture

Highest availability with dual channel design

State-of-the-art communication (Modbus, Profibus, IEC61850)
Low engineering costs - all functions in one casing
Low commissioning costs - comfortable HMI, sophisticated PC tool

(Modbus, Profibus, IEC61850)

-
- ,
© ABB Group
June 4, 2012 | Slide 61
 On board DC-grid
UNIREC

UNIREC

© ABB Group
June 4, 2012 | Slide 62
Onboard DC grid /
Scope of Supply

© ABB Group
June 4, 2012 | Slide 63
Summary
UNIREC UNIREC

Options UNIREC LV

GENREC-L => left side connection

GENREC-R => right side connection

© ABB Group

Month |
DD, Slid
Onboard DC grid
Overview Basic

© ABB Group
June 4, 2012 | Slide 65
Onboard DC grid
EXC and GENREC
EXC (Excitation) GENREC (Generator Rectifier)

© ABB Group
June 4, 2012 | Slide 66
 Software tools

© ABB Group
June 4, 2012 | Slide 67
UNITROL software products UNITROL ®
ECT software, CMT 1000 tool ECT , CMT 1000

Excitation Control Terminal (ECT) SW

User-friendly tool for operation, monitoring and
maintenance of UNITROL 5000 and UNITROL
6000 excitation systems
(ECT)

UN5000 UN6000

CMT 1000 Tool

Commissioning and maintenance tool for UNITROL
1000. Enables controlling, monitoring, maintenance
and programming of the products
CMT 1000
CMT1000 UN1000
UN1000

© ABB Group
June 4, 2012 | Slide 68
UNITROL software products UNITROL ®
SMTS, SMTS-RT 6000 SMTS, SMTS-RT 6000

Synchronous Machine Transient

Simulation (SMTS)
The program allows the user to carry out simulations
involving a synchronous machine. SMTS includes
model of a turbine and a network.

(SMTS)
SMTS

Synchronous Machine Transient

Simulation Real Time (SMTS-RT 6000)
The tool enables real time simulation (for studies,
training and other purposes) and closed-loop tests of
the excitation systems.

(SMTS-RT 6000)

© ABB Group
June 4, 2012 | Slide 69
Synchronous Machine Transient Simulation
Simulation environment

© ABB Group
June 4, 2012 | Slide 70