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
2011

13.5
380
1988
1883

ABB
ABB Group
June 4, 2012 | Slide 4

1891

Power and productivity for a better world

ABBs vision
ABB

As one of the worlds 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
ABBs 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 ABBs 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
,
ABB Group
June 4, 2012 | Slide 7

,
,

AGH

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
2011
6,600

: 33.6
: 35.7

ABB Switzerland Locations

ABB
Headquarters
1

12

Baden
Engineering/
production location

3 I
4 5 6
7
8

II

Lenzburg
11

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

ABB Group
June 4, 2012 | Slide 10

III

IV

13
10
9

Regional sales office

Baden
II Zuzwil
III Bern
IV Lausanne
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
Traction DC substations
MV Power Converter Systems
17 Hz rail power converters
AC excitation
MV STATCOM
MV Power Converter Products
MV wind power converters

LV Power Converter Products

Active voltage conditioners
Battery and fuel cell converters
Marine frequency converters
ABB Group
June 4, 2012 | Slide 12

BORDLINE
Propulsion converters
for trains and locomotives
BORDLINE
Auxiliary converters
for onboard power supply
BORDLINE
Battery chargers

ACS 1000 / 1000i

0.3 5 MW
ACS 5000
2 22 MW
ACS 6000
3 27 MW
MEGADRIVE-LCI
2 72 MW (or higher)

Metals

Mining&Minerals

Oil & Gas

Power

Marine

Water

Power Electronics and MV Drives

Global footprint and key locations

PRU OEM Packs

MVD Service Hub
LEC Excitation
LEC Rectifiers
LEC Power Conv.
Sales MV Drives
R&D MV Drives
LCC Factory in MX

PRU Excitation
PRU Rectifiers
PRU Power Conv.

LCC Factory in PL

PRU Traction Conv.

PRU MV Drives
PRU Service

Sales MV Drives

LEC Excitation
LEC Rectifiers
Sales MV Drives

ABB Group
June 4, 2012 | Slide 13

Sales MV Drives

Sales MV Drives
LEC Excitation
LEC Rectifiers
LEC Traction
Assbly. MV Drives

LEC Excitation
LEC Rectifiers
Sales MV Drives

PRU
LEC
JV

LEC Excitation
JV Rectifiers
JV Traction
Assbly. MV Drives

LEC Excitation
LEC Rectifiers
Sales MV Drives
PRU LV Power Cv.

Power Electronics and MV Drives

Global center of competence (Switzerland)
ABB

ABB

, Turgi

ABB

ABB
Lenzburg
ABB Group
June 4, 2012 | Slide 14

Dttwil

Power Electronics and MV Drives

Center of excellence
PE and MV Drives center in Turgi, Switzerland: ABBs
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
Schaffhausen
Baden
Turgi
Daettwil
Birr
Zurich
Lenzburg

Number of employees
900

Berne

Lausanne

Geneva

ABB Group
June 4, 2012 | Slide 15

Pregassona

900

Excitation business

ABB Group
June 4, 2012 | Slide 16

ABB Switzerland
Global Product Line Excitation Systems
ABB

Aija Mankkinen
Assistant: I. Schwammel

Bahman Kazemi

Sergio Nienartowicz

Pierre Enstedt

Hans-Jrg Herzog

Tobias Keller

Rudolf Wieser

Michael Locher

Bangalore
Ramesh K.

Marketing Communication

Development & Support

Sales

Sales Service

Electrical

LEC Support

Product Management

Electrical Engineering

Operation Service

VAR Support

Mechanical Engineering

Product Sales

Project Management

Component Sales

Factory

ABB Group
June 4, 2012 | Slide 17

Engineering
Mechanical
Engineering
Commissioning

Global Product Line Excitation Systems

Excitation Products and Technology

Tobias Keller

Stephan Egli
Peter Moor

Development & Support

Valerijs Knazkins

Tobias Keller

Georg Meier

Rudolf Moeckli

Matthias Bchle

Werner Zimmerli

Dietmar Ebner
David Stutz
Patrick Vandekerckhove

ABB Group
June 4, 2012 | Slide 18

Product Management

Wolfgang Knapp

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
AUXILIARY
SYSTEMS

HV-breaker

Governor
1

Control systems

Aux. Protection
Transf.
Generato
r
breaker

Static starter

PTs
&
CTs
Synchronizing

Star
point cubicle
ABB Group
June 4, 2012 | Slide 20

Excitation system

SYNCHRONOUS
GENERATOR

TURBINE

Excitation
transformer

Excitation systems and synchronizing equipment Brands

UNITROL
Excitation systems

MEGATROL
Static frequency converter and
static excitation system in one package

SYNCHROTACT
Synchronizing equipment

UNIREC
ABB Group
June 4, 2012 | Slide 21

Main Generator Rectifier and Excitation

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
One of the largest
SES worldwide

ABB Group
June 4, 2012 | Slide 23

2001

:
: Ifn = 9,750 A / Ufpl = 1,392 V

References
Itaipu HPP / Brazil - Paraguay
/
Plant extension
Delivery year 2003
The largest HPP
worldwide

Customer: Itaipu Binacional

2003

Machine data: 9 x 823 MVA / 50Hz,

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
Delivery year 2011

ABB Group
June 4, 2012 | Slide 26

2011

: Ifn = 9, 265 A / Ufpl = 1,020 V

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

AVR

Keep machine within permissible operating range

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

ABB Group
June 4, 2012 | Slide 31

1000

UNITROL 1000 product family

until end of 2011
UNITROL 1000
2011

UNITROL 1000-15

ABB Group
June 4, 2012 | Slide 32

UNITROL 1000-PM40
Power module

UNITROL 1000-7

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
UNITROL 1010

UNITROL 1020

10 A cont.
20 A ceiling

20 A cont. *
38 A ceiling

Aux power supply

YES

YES

Panel

NO

YES

8 digital I/Os
4 digital input
3 analog inputs
2 analog outputs

8 digital I/Os
4 digital input
3 analog inputs
2 analog outputs

USB
RS485
Ethernet
(CAN)

USB
RS485
Ethernet
(CAN)

IP20
Low module height

IP20

*) Ie > 15 A requires
external capacitor

Excitation current at 55
C
55 C

I/Os

I/O

Interfaces

Mechanicals

Mounted inside generator

ABB Group
June 4, 2012 | Slide 34

Mounted inside generator

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)

PIN6080

Channel#2
CCM6080

PIN6080

CCM6080

Channel #1

CIO
#1
CIO #1

1)
SM/SG
Discharge

ABB Group
June 4, 2012 | Slide 36

Field
flashing

UNITROL 6080

UNITROL 6000 excitation systems

UN6080 AVR, 25-60A indirect excitation

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
UN6080 AVR, 25-60A

UNITROL 6000 excitation systems

UN6080 prepared to meet customer requirements
UN6080
Aux.Li
ne Hz
50/60

-Q71

-K71

Supply transfer

Aux.Li
ne Hz
50/60

Batter
y

Batter
y

-Q72

-Q71

-Q72

-K72

-K71

-K72

AC-field circuit
breaker

-T04

-T04
-F60 -Q80 -F63
-T60

-F60 -Q80 -F63

-T63

-T63

-T60

-Q03
-V80

-V80
Aux.
Power
-Q10

-Q20

-A10

-Q12

-Q30

-A20

CH 1

CH 2
-Q22

-R02

Aux.
Power
-Q10

-Q20

-A10

-A30

BFCR

CH 1

-Q32

-Q12
-A02

-Q30

-A20

CH 2
-Q22

Converter
protection and
on-line
maintenance

-A30

BFCR
-Q32

On-line
maintenance

S007
-Q02
-R08
MOV

R
02

- V T
02 02

DC-field circuit
breaker

ABB Group
June 4, 2012 | Slide 38

UNITROL 6000 excitation systems

UN6080 single channel static excitation

Hydro power plant

7 MVA / 6.4 kV
SES

7 MVA / 6.4 kV
SES

ABB Group
June 4, 2012 | Slide 39

UNITROL 6000
UN6080

Excitation systems

UNITROL 6800 medium

to large SES

UNITROL 6800

ABB Group
June 4, 2012 | Slide 40

UNITROL
UN6800

UNITROL 6000 excitation systems

UN6800 controller and power converter

AC 800PEC controller

AC 800PEC

UN6800 SES

Measurement signals

Parallel converter operation

Optical data link

Thyristor gate control

Backup
control &
protection
Control
channel#1

Converter

Converter
control

Control
channel #2
I/O device
IO Device

IO Device

SG

Discharge

ABB Group
June 4, 2012 | Slide 41

Field
flashing

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
600 MHz
64
ABB Group
June 4, 2012 | Slide 43

IEEE

ABB Control Builder

Power PC CPU (IBM)

Excitation systems
UN6000 Summary
UN6000

ABB Group
June 4, 2012 | Slide 44

UNITROL excitation systems product portfolio

Comparison major characteristics UN6080 / 6800
UN6800 static excitation system (SES)
UN6800
(SES)

Optional

UNITROL
UN6080 / 6800

UN6080 AVR and SES

UN6080 AVR
SES

Measurement signals

Measurement signals

Optical data link

Optical data link

Thyristor gate control

Thyristor gate control

to be used alternatively or both

1)
1)

Converter#1

Channel#2

PIN6080

BFCR
CCM6080

PIN6080

Converter
control

Control
Channel # 2

PIN6080

Control
Channel#1

CCM6080

Channel #1

CCM6080

Backup
control &
protection

I/O IO
device
Device

IO Device

CIO
#1
CIO #1

1)
SG
SM

Basic I/O
Direct hard wired

SM/SG
Discharge

Field
flashing

Discharge

UNITROL 6800

ABB Group
June 4, 2012 | Slide 45

Field
flashing

UNITROL 6080

UNITROL excitation systems product portfolio

Comparison major characteristics UN6080 / 6800
UN6800 static excitation system (SES)
UN6800
(SES)

UNITROL
UN6080 / 6800

UN6080 AVR and SES

UN6080 AVR
SES
UN6080

UN6800
Single, double, triple redundant control

Single, double, triple redundant control

Up to 8 converters in parallel operation

n-1, n-2 (hot standby)

1 converter in operation
1 or 2 redundant converters
1+1 (cold standby)

Independent controller and converter

redundancy

Controller and converter operate as one unit

10 1,600 ADC

1,600 10,000 ADC

UN6800

n-2

UN6080

8
(

n-1,
)

1,600 10,000 ADC

ABB Group
June 4, 2012 | Slide 46

1
1
2
1+1 (

10 1,600 ADC

Excitation systems
Power System Stabilizer
PSS

ABB Group
June 4, 2012 | Slide 47

Power System Stabilizer (PSS)

Available types

(PSS)

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 4B

PSS
(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

Service Control Panel (SCP)

UNITROL 6080/
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

Excitation Control Terminal (ECT)

UNITROL 6080 / 6800

(ECT)

Benefits
W x D x H (mm)
483 x 355 x 90
Weight 7.3 kg

W x D x H (mm)
483 x 355 x 90
7.3 kg

Comprehensive data acquisition and

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

ABB Group
June 4, 2012 | Slide 51

PC

UNITROL 6080 / 6800

Excitation Control Terminal (ECT)

ABB Group
June 4, 2012 | Slide 52

UNITROL 6080 / 6800

(ECT)

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
EXC ON

ABB Group
June 4, 2012 | Slide 54

Synchronizing

Excitation Current IEN /A

MEGATROL product Line

Static excitation current, SSD starting power

ABB Group
June 4, 2012 | Slide 55

MEGATROL
, SSD

MEGATROL Light
Arrangement

ABB Group
June 4, 2012 | Slide 56

MEGATROL

MEGATROL

ABB Group
June 4, 2012 | Slide 57

DCS #2

DCS #3

Unit #3

Unit #1

DCS #1

DCS #4

DCS #5

Unit #5

MEGATROL
Cross start

DCS #6

Synchronizing equipment

SYNCHROTACT

SYNCHROTACT

ABB Group
June 4, 2012 | Slide 58

SYNCHROTACT synchronizing equipment

Generator synchronizing and paralleling of lines
SYNCHROTACT

U1

SYNCHROTACT

CMD
CB
U2
AVR

G
ABB Group
June 4, 2012 | Slide 59

GV

U+
Uf+
f-

S 99003

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
Advantages and benefits

SYNCHROTACT

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

ABB Group

Month
DD,

|
Slid

GENREC-L

=> left side connection

GENREC-R

=> right side connection

Onboard DC grid
Overview Basic

ABB Group
June 4, 2012 | Slide 65

Onboard DC grid
EXC and GENREC
EXC (Excitation)

ABB Group
June 4, 2012 | Slide 66

GENREC (Generator Rectifier)

Software tools

ABB Group
June 4, 2012 | Slide 67

UNITROL software products

ECT software, CMT 1000 tool

UNITROL
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

ABB Group
June 4, 2012 | Slide 68

UN1000

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