System-based Automation

State-of-the-art automation & control systems have to guarantee the simple and safe operation of a hydro power plant.

Typically there are different possibilities for local control (e.g. unit control board) as well as remote control (central control room and/or dispatching centre).

In emergency situations the system has to lead the corresponding part of the plant to a predefined, safe operating state automatically.

The essential requirements to a hydro power plant automation & control system are easy adaptation to the existing plant and separation into independent functional parts. The overall control of the plant needs to take care of operational regulations as well as the primary systems (e.g. unit, dam gate) require an integrated control of these parts.

All process signals should be managed without multiple engineering.

In order to allow an easy future expansion, the local and remote communication of the system has to be based on international communication standards.

Reduction of spare parts by using one hardware platform as well as the reduction of maintenance and service activities by integrated remote diagnostic functions should reduce the maintenance costs to a minimum.

Step-by-step expansion and the integration of further parts of the plant (e.g. switch yard, station service) should easily be possible at any time.

The Common Solution

Dividing the overall system into autonomous functional areas increases the availability of the total plant. The definition of different functional areas are the result of your structural conditions and depends on your primary technology (units, dam gates, switchyard). In normal operation, the corresponding part of the process is monitored and controlled, whereas in case of emergency, switchover to a safe operation state will be performed.

• Functional area "Unit Control Board"
  In addition to the basis layout of the unit control board (compact or decentralised, singular or redundant configuration), the availability can additionally be increased by subsplitting the unit control board into functional islands. Direct process and transformer interfaces (binary 220 VDC, VT/CT 100/110/220 VAC, 1/5 A) cut down the costs of the process interface level by reduction of interposing relays, transducers and terminal points. Modern touch panel PC's are used as the standard solution for the local control.

• Functional area "Central Control Room"
  The HMI system in the local control room of the power plant can be configured as compact system or as a redundant multi-user system. Based on project experience over many years we can easily adapt our standards to your operational requirements (process displays, user guidance, alarming concept, reporting, ...).

• Functional area "Switch Yard"
  The automation of the functional area switchyard is based on the proven centralised or decentralised configurations using the same hardware platform as the unit control board.

Our Products

• SICAM 1703
  The automation & control system SICAM 1703 is characterised by innovative system concepts, 32-Bit multi-processor technology, powerful communication capabilities and one unique engineering tool. Based on optimised mechanical modular design, signal numbers adapted to the process needs and direct process interfaces (e.g. voltage transformer) the system ideally fits for decentralised as well as centralised concepts. Due to design for industrial use, the system withstands the climatic and electro-magnetical environmental conditions easily.

• 250 SCALA
  The 200 product family represents a full-featured modern SCADA-system for hydro power plants. Integrated scalability allowing the use in all applications leading from local operation via touch-panel through local control rooms to huge main control centres and ergonomically HMI-concepts are the basis for safe operation of the process.

• HyNET
  The HyNET product family is the basis of the safe communication in the power plant automation system. It interconnects all internal relevant components inside and outside of the plant. The communication concept makes use of LAN/WAN-technologies as well as conventional communication and will be especially selected and adapted according to the plant requirements

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

Flexible Turbine Control

State-of-the-art turbine controllers must meet the highest demands concerning safety, economy 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 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. 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 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 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.

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.

• 250 SCALA
  The 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, ....

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

• 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.

• HyNET
  The HyNET 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.

• 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.

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Sensors take the heat

Greenwich University researchers are to work with Oxsensis on the development of sensors that can measure pressure and temperature at more than 1,000C.

Greenwich University researchers have won a SPARK award to work with Oxfordshire-based Oxsensis on the development of sensors that can simultaneously measure pressure and temperature at more than 1,000C.

Prof Chris Bailey, who leads the Computational Mechanics and Reliability Group in the School of Computer and Mathematical Sciences at the university, will use computer modelling techniques to predict how the sensors and their components would operate under different conditions of fluid flow, temperature and vibration.

The research will help Oxsensis with the design, assembly and installation of the sensors, which operate deep inside combustion engines.

Prof Bailey said: 'The aerospace and car manufacturing industries are demanding improved sensors because next-generation engines are getting much hotter. At the moment, no sensor can work reliably above 800 degrees.'

The two partners will start working together this month.

Oxsensis, which was formed in 2003 as a spin-out from Rutherford Appleton Laboratory, is developing sensor technology based on the micromachining of super-resistant materials such as single-crystal sapphire (melting point >2,000C) together with innovative fibre-optic interrogation techniques that give high sensitivity and immunity from electro-magnetic interference effects common in turbo-machinery such as gas turbines.

The SPARK awards, which started in 2002, are given to higher education institutions that help small and medium businesses tackle a problem of direct relevance to them. They also aim to encourage longer-term relationships between educational and business organisations.

The SPARK awards are organised by the Integrated Products Manufacturing Transfer Network, one of the Knowledge Transfer Networks of the Technology Strategy Board, jointly with the Innovative Electronics Manufacturing Research Centre (leMRC) of the Engineering and Physical Sciences Research Council.

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