Power plant products |
Upgrade of GT controls at Singapore power
ABB has been commissioned to upgrade one of the turbine control systems at the 1300 MW Keppel Merlimau Cogen (KMC) combined cycle gas turbine on Jurong Island in Singapore, to improve efficiency and reliability. The scope includes replacing the existing Egatrol 8 turbine control system with Egatrol X, which is based on the ABB Ability System 800xA flagship distributed control system (DCS) and modern AC800M portfolio.
Transferring full functionality from the existing application to the updated solution allows the customer to avoid downtime and
install the control system in the shortest possible time. The project involves upgrading DCS components while keeping the overall structure as far as possible. Instead of having to rebuild the entire system in one go, ABB will provide a flexible, customised approach whereby older components are replaced as and when needed. This prevents unnecessary downtime, avoids the costs associated with loss of operation, and helps provide a stable, reliable energy supply with high availability. All control settings are adopted through an in-house software code conversion process,
eliminating time-consuming adjustments of system parameters. The user interface, based on System 800xA, only requires minor adjustments, which eliminates operator retraining. The hardware design, featuring ABB’s latest I/O evolution kit, significantly reduces commissioning time and eliminates the risk of re-wiring errors.
As part of Singapore’s commitment to achieving net zero emissions by 2050, the government is driving business transformation through grants for energy efficiency and emissions reduction. It is also investing in low carbon technologies to progress the energy transition. With power generation currently accounting for 40 % of carbon dioxide emissions, the country plans to diversify its energy supply with a focus in four areas: solar, regional power grids, emerging low-carbon alternatives including hydrogen, and natural gas.
While natural gas continues to play an important role, as the country expands its energy portfolio, the KMC project is expected to showcase how operators can enhance energy and carbon efficiency in gas power generation. This initiative not only safeguards current energy security but also supports the integration of renewable energy into the grid, driving forward shared energy transition goals. The project is part of KMC’s ongoing initiative to adopt automation solutions to boost system reliability and responsiveness, enhance efficiency, lower fuel costs, and achieve a reduced environmental impact.
World’s first medium voltage, speed- controlled motor concept
ABB says that its MV Titanium concept is the world’s first medium-voltage, speed controlled, industrial motor, in the 1-to-5-MW range and that it brings connectivity and control features in an easy to specify and install package. The all-in-one concept is said to bring the benefits of energy efficiency to MV motor-driven processes, which are said to account for 10% of the world’s electricity demand.
“Energy efficiency measures of speed- controlled motors have gained significant traction in small size motors, for low voltage applications. But large motors have so far been left behind, due to initial cost and complexity, with only 10-15 % currently connected to a drive,” says Heikki Vepsäläinen, president of ABB Large Motors and Generators. “But that is set to change with our new MV Titanium concept that makes it cost-effective and straightforward to install a suitable matched motor … it is the right upgrade solution for existing direct-on-line motors. And the potential savings in energy
costs and CO2 emissions are huge – if we
retrofitted the entire installed base, it would be like taking just over 1000 coal-fired power stations offline.”
ABB has developed the MV Titanium concept to address the main perceived obstacles related to installing a drive with a large motor. These include not only the initial cost of a separate drive, but also its associated electrical housing, transformers, switchgear and cabling that multiply the capital cost and increase the complexity of installation. In addition to these savings, it will also provide OPEX savings. Furthermore, it has intelligence built in, with analytical and connectivity capabilities so it can seamlessly integrate into existing systems, as well as providing software libraries and interfaces for process monitoring and optimisation.
The MV Titanium motors are intended for use with pumps, compressors, and fans as typical applications, where they could reduce energy
40 | September 2024|
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consumption by up to 40 % as well as enhancing productivity and minimising downtime. They are applicable across a wide range of sectors including power and renewables, processing, mining, cement, and water.
Heikki Vepsäläinen again: “[This concept] puts ABB well on the road to support changing large, fixed speed motors to fully electrically controlled motors, one by one.”
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