Application Bulletin CEMEX Corporation Woodward Solution solves Cebu utility issues and APO Cement Plant experiences stability in power PMCS-B-0004-10 BACKGROUND With more than 100 years of history, CEMEX has become one of the leading cement companies, with approximately 80 million metric ton of annual production capacity. CEMEX has wide spread of operations in more than 30 countries and trade relations with more than 60 countries with extensive network of distribution channels. CEMEX entered Asia in 1997 through Philippines. In 1999, APO Cement Corporation was acquired by CEMEX where it is located at Tina-an, Naga City, Cebu, Philippines. The plant in Cebu is producing massive volume of cement production, thus utility is not able to support the demand. CEMEX then built self-power house with 6 units of Sulzer diesel generators providing power to support their daily operation. Individual generator is rated at 14MVA capacity. In order to minimize power interruptions due to power shortage in Cebu-Negros, Philippines government linked company – Panay utility (CNP), Visayan Electric Company (VECO) enter into a Power Supply Agreement with CEMEX. CEMEX will have to supply 10MW of power to VECO during peak power demand hours. CEMEX will then import power from VECO during off peak power demand hours. But the existing power system in CEMEX did not have the capability to tie to utility. CEMEX consulted PM Control Systems (PMCS) after knowing PMCS had provided a similar governor and power management retrofit in a Mactan 50MW power plant. After reviewing the PMCS proposed application solution, CEMEX awarded the project to PMCS. The scope of supply consisted of retrofitting existing ABB DEGO II governor, its electric ASAC 70 actuator, its old RG87 synchronizer and the obsolete GEC Alsthom excitation control system to Woodward 828 Digital Speed Control, EM80 electric actuator, Easygen 3200 and Basler DECS 300 AVR. The combined SPM-D10 and IKD1 module were also added to provide a tie-in to the utility to achieve import/ export feature. New power management control provided function to detect utility fault and make swift action to swing online generator sets from droop to isochronous load sharing. Solutions • Solution provider - PM Control Systems • Woodward digital control system and power management solution - 828 Digital Control - EM-80 Actuator - Easygen 3200 - Basler DECS 300 AVR Results • Operational impact - CEMEX is able to meet the requirement for exporting power to VECO during peak power demand hours as well as importing power from VECO during off peak power demand hours. • Reliability impact - With the implementation of exporting power to the utility during peak demand hours, Cebu province experiences a more reliable power and has less power outages as compared before the retrofitting. • Community impact - It recognizes CEMEX’s continuing commitment to help sustain the progress and the development of Cebu. Copyright by APO Cement Corporation
Transcript
Application Bulletin CEMEX Corporation
Woodward Solution solves Cebu utility issues and
APO Cement Plant experiences stability in power
PMCS-B-0004-10
BACKGROUND
With more than 100 years of history, CEMEX has become one of the leading cement companies, with approximately 80 million metric ton of annual production capacity. CEMEX has wide spread of operations in more than 30 countries and trade relations with more than 60 countries with extensive network of distribution channels. CEMEX entered Asia in 1997 through Philippines. In 1999, APO Cement Corporation was acquired by CEMEX where it is located at Tina-an, Naga City, Cebu, Philippines. The plant in Cebu is producing massive volume of cement production, thus utility is not able to support the demand. CEMEX then built self-power house with 6 units of Sulzer diesel generators providing power to support their daily operation. Individual generator is rated at 14MVA capacity. In order to minimize power interruptions due to power shortage in Cebu-Negros, Philippines government linked company – Panay utility (CNP), Visayan Electric Company (VECO) enter into a Power Supply Agreement with CEMEX.
CEMEX will have to supply 10MW of power to VECO during peak power demand hours. CEMEX will then import power from VECO during off peak power demand hours. But the existing power system in CEMEX did not have the capability to tie to utility. CEMEX consulted PM Control Systems (PMCS) after knowing PMCS had provided a similar governor and power management retrofit in a Mactan 50MW power plant. After reviewing the PMCS proposed application solution, CEMEX awarded the project to PMCS. The scope of supply consisted of retrofitting existing ABB DEGO II governor, its electric ASAC 70 actuator, its old RG87 synchronizer and the obsolete GEC Alsthom excitation control system to Woodward 828 Digital Speed Control, EM80 electric actuator, Easygen 3200 and Basler DECS 300 AVR. The combined SPM-D10 and IKD1 module were also added to provide a tie-in to the utility to achieve import/ export feature. New power management control provided function to detect utility fault and make swift action to swing online generator sets from droop to isochronous load sharing.
Solutions • Solution provider
- PM Control Systems • Woodward digital
control system and power management solution - 828 Digital Control - EM-80 Actuator - Easygen 3200 - Basler DECS 300 AVR
Results • Operational impact
- CEMEX is able to meet the requirement for exporting power to VECO during peak power demand hours as well as importing power from VECO during off peak power demand hours.
• Reliability impact
- With the implementation of exporting power to the utility during peak demand hours, Cebu province experiences a more reliable power and has less power outages as compared before the retrofitting.
• Community impact
- It recognizes CEMEX’s continuing commitment to help sustain the progress and the development of Cebu.
Copyright by APO Cement Corporation
Application Bulletin CEMEX Corporation
CHALLENGE
VECO and CEMEX were responsible for the interconnection between the utility and the existing power system through bus tie and mains breakers as shown in the Overview section. Existing control systems are listed as below: • ABB DEGO II system • ASAC70 actuator • GEC Alstom AVR • RG87 synchronizer for GCB Detailed site survey and studies were made and conducted together with CEMEX and various companies. Technical information and requirements were shared during the visits. Follow-up meetings were conducted making sure project milestones were met on time. The proposed systems was planned to replace existing units which were mounted in stretch of walk through panels. Considerations had to be taken in designing mounting brackets and plates to support the new controls, since mounting methods differed after two decades. It was almost impossible for two people to work back to back in a confined space of the narrow walk through panels. Due to the distant between the engines and control room, proposed field cables had to be selected carefully. These field cables had to be laid in tray with limited space, bending radius of individual cable was another factor to take note of. In the midst of engineering phase, CEMEX entered an Operation & Maintenance agreement with Wartsila. Communication channel and work responsibility posed a challenge to the initial site project execution and timeline. Through our PMCS project team sheer constant communication with Wartsila and CEMEX, issues were cleared and project milestone was put on track again.
CEMEX would only allow one engine to shut down for upgrade at any one time due to the high plant load demand. At any time four 11.2MW engines had to be operated at full load and one engine kept as standby. Careful studies and measures were undertaken to make sure all required I/O signals were identified and the change-over to new equipment would not pose an upset to the online critical units. New speed control functions were tested including the excitation control logics. During the logic function test, huge fluctuations of the frequency and voltage caused black-out to the plant. PMCS and Basler representative worked frantically to determine the cause. Finally the root cause was found and confirmed the PMG source was sending an unstable signal to the sensing input of the AVR. As a result it affected the AVR control stability. After deliberating with CEMEX and Wartsila, the AVR sensing input was re-wired to tap direct from the generator bus. The result proved to be working normally. Other technical challenges involved replacing the EM80 actuator’s lever to allow the engine to carry maximum load and tuning each Easygen 3200 to obtain the best optimum export setting when multiple generators were in parallel with utility. Though the project was faced with several technical issues and project schedule was slightly affected CEMEX was satisfied with the overall commissioning.
SOLUTION
The following items were proposed, supplied and installed by PMCS: • Woodward 828 Digital Control • EM-80 driver and actuator • Basler AVR DECS-300 • Woodward Easygen 3200 • Woodward SPM-D • Woodward IKD 1
Replacement of old actuator to EM-80
Replacement of ABB DEGO II system to Woodward 828 Digital Control
Replacement of AVR control and Power Panel
Application Bulletin CEMEX Corporation
Woodward 828 Digital Control 828 Digital Control replaced existing ABB DEGO II system. It controlled and regulated the engine speed from the feedback of two proximity speed sensors. The control accepts speed biasing output from Easygen for engine speed regulation during no load to full load operation. EM-80 Driver and Actuator It replaced the existing ASAC70 actuator. The EM Driver controls the actuator position proportion to a position demand signal (4~20mA) receives from 828 digital control. It provides actual position readout (1~5V) to PLC for SCADA HMI as well. IKD 1 Expansion Board It is an expansion I/O for Easygen 3200 communicating through the CAN bus to send a common bias signal to all Easygen 3200 units for group breaker synchronising Easygen 3200 The following features are provided by Easygen 3200: • Generator and main breaker
Control • Isochronous load sharing when
bus tie breaker is open via CAN bus
• Import/Export power through a key selector switch
• Biasing outputs to 828 digital control and DECS-300 AVR
• Configurable trip levels for monitoring and protective functions
• Receives export MW setpoint broadcast from PLC/SCADA HMI through serial RS485 using ModBus
SPM-D -Synchronizer The SPM-D is a microprocessor-based synchronizer.
It is responsible for closing of Bus Tie breaker. It provides automatic frequency and voltage matching using discrete output bias signal from IKD 1 expansion board (an expansion I/O for Easygen). RS 485 ModBus Link All units of Woodward 828, Easygen 3200 and DECS-300 were daisy chained together using RS 485 ModBus for data monitoring on the PLC/SCADA HMI. Basler AVR DECS-300 The old AVR control was replaced with a microprocessor based control DECS-300 for better reliability and control. The existing power section of the voltage controlled system was also replaced. DECS-300 control also received voltage biasing signal from Easygen for auto synchronizing of generator breaker to the bus. Together with above controls, PMCS had implemented a solution to fit CEMEX’s requirements, fulfilling VECO import and export needs and self sufficient to daily cement operations in CEMEX. CONCLUSION
All the old controls were replaced with new controls supplied by PMCS. Retrofitted controls were successfully tested and commissioned. The new power system was able to handle import/export when tied to utility and load sharing when system is in island mode. PMCS had enhanced the current efficiency with an increase load of 20%, this enables CEMEX to export more power during peak hour to VECO with more commercial benefits. These experiences confirm PMCS as a total solution provider for Power Generation and are capable of providing quality and reliable support to our client, CEMEX.
Taking measurements for Panel mounting
Easygen 3200 and DECS-300 Panel
Application Bulletin CEMEX Corporation
OVERVIEW
New Power Plant System Setup Commissioned project
For more information, please contact:
PM Control Systems Pte Ltd No. 8 Joo Koon Crescent Singapore 629011
Indonesia office: PT PM Control Systems Sentra Bisnis Artha Gading Blok A 7C/25 Kelapa Gading Jakarta Utara, Indonesia Tel: +62 21 4585 7266 Email: [email protected]
Australia office: PM Control Systems Pty Ltd Unit 1, 1 Wirega Avenue, Kingsgrove, NSW 2208, Australia Tel: +612 9758 2322 Email: [email protected]
