LOYYANGBPOWER STATION
Morwell, Victoria, Australia
A CaseStudy on KRONE Industrial Wiring Products
Scope: Application of KRONE terminal modules within the Instrumentation
and Control Wiring System of LoyYangBPower Station
Date: February 1996
Prepared by: Martin Breiesser, Sales & Marketing Engineer
Power & Control Division,
KRONE (Australia) Technique Pty Limited
Project Background
In 1986, the State Electricity
Commission of Victoria (SECV)
commenced the initial design of the
Loy YangBpowerstation at Morwell
– in the coal rich Latrobe Valley in
Victoria, Australia.
The SECV had excellent experience
with the KRONE terminal modules,
used in the telephone distribution
systems at the older LoyYang A
power station. This prompted them
to research the use of KRONE
modules in the instrumentation and
control system of LoyYang B.
During the planning stage, Mr
Chapman of the SECV Cabling and
Layout Section and Mr Kerr of
KRONE (Australia) co-developed a
new range of products. The new
products were to accept the cable
types that the SECV were planning
to use and withstand the harsh
environmental conditions of a coal
power station.
Previously, all cable terminations for
this area had used traditional screw
type, DIN-rail mounted terminals
(Typically Weidmüller/Klippon -
SAK2.5, SAKR2.5 and SAKT2).
The SECV’s recommendations for the
Loy YangB specification requested
that: “Industrially standard practice
using commercially standard material
is recommended for all applications
where possible. Terminations are
subject to the same constraint to
reduce on-site labour and material
costs where possible.”.
With this recommendation in place,
KRONE (Australia) worked with SECV
over the following two years to
develop a complete system concept
for control and instrumentation
wiring.
During this time, KRONE had to
convince the engineers, specifiers
and installers at all levels that the
KRONE Insulation Displacement
Connection technology (LSA Plus)
was completely suitable for this
application. The major objections
presented to KRONE were overcome
by the development of the
Instrumentation Module (accepts up
to 0.9mm
2
cable) and the KRONE
LSA to Screw Module. The
development of the “S” Tool, to
correctly insert and cut the wire was
also critical.
By 1988, all parties were satisfied
with the KRONE system and the
specification for cabling was
released, nominating LSA Plus
terminal modules and associated
products.
Construction of LoyYang B
commenced in 1990 and the power
station was commissioned on-line in
1994
Specifications
Loy YangBPower Station
Constructed by SECV, now owned
and operated by Mission Energy
Output: 2x500MW Generators
Fuel: Brown coal
Cabling Details: Over 250,000
terminations completed in KRONE
LSA Plus technology (turbine house
and boiler).
Typical operating voltages 24V and
48V DC
Cabling Contractors: Station and
Boiler cabling contracts installed by
Siemens Ltd, Australia.
Control Equipment: Bailey Control
and Siemens Ltd, Australia
Cable Details: Multipair
instrumentation cable 2-100 pairs
(B50 Procon) manufactured by MM
Cables, Australia
Cable strandings: copper 1/0.64,
1/0.9, 7/0.2, 7/0.25, 7/0.30 and
7/0.50
Cable
Marshalling
Cubicle (CMC)
Cable Route
= KRONE terminal
modules installed
Cable
Marshalling
Cubicle (CMC)
Programmable
Logic
Controller (PLC)
Main
Processor
PC/Terminal
Man/Machine
Interface
Cable Junction
Box (CJB)
Instrumentation
Junction
Box (IJB)
Fig 1: Overview of Instrumentation and Control Cable Marshalling System
Cable Marshalling Cubicles
Cable Marshalling Cubicles (CMC)
are designed to marshal
instrumentation cables within the
unit control equipment rooms and
the station control equipment room.
The outgoing field cables were
terminated on the bottom side of the
KRONE modules and routed through
the PVC cable ducting.
The incoming cables enter through
the top of the enclosure, through the
stand-off brackets and into the rear
of the KRONE backmount frame.
The size of the stranded Multipair
instrumentation cable used was
0.5mm
2
(7/0.30).
The CMC enclosures were specifically
designed by KRONE to maximise the
space savings. The cubicle design is
based on the KRONE 600 pair wall
mounted distribution frame with the
jumper ring bars replaced by slotted
PVC cable duct.
The contract specified 42 CMC’s to
be installed:
• turbine house cabling 32
• boiler cabling 10
Cable Junction Boxes
Cable Junction Boxes (CJB) are
intended for mounting close to
major plant items.
The CJB’s are used for the
connection of small local cables and
for marshalling into groups of
terminals, separated adequately for
differing levels of circuit voltages.
The CJB is normally connected to the
CMC via a large multicore
instrumentation cable, up to 100
pairs, and to the IJB by multicore
instrumentation cable, from 2-20
pairs (usually 0.5mm
2
, 7/0.30).
The contract specified 176 CJB’s to
be installed in LoyYang B.
• turbine house cabling 120
• boiler cabling 56
Instrumentation Junction
Boxes
In the Instrumentation junction Boxes
(IJB), sensors, limit switches,
thermocouples and other field
devices are directly connected to the
plant control circuitry.
Often the field devices have very
small cables fitted and it is at the IJB
that they are interfaced with larger
multicore cables such as 2, 4 and 8
pair. Often 2.5mm
2
(7/0.67) cable is
used for voltage drop protection.
The IJB is normally connected to the
CJB via multicore instrumentation
cables (usually 0.5mm
2
, 7/0.30) from
2-20 pairs.
At the time LoyYang B, was being
constructed, KRONE did not have a
product suitable to terminate LV
power cable up to 2.5mm
2
.
Since then, KRONE has launched a
range of terminal modules,
specifically designed for LV
applications (up to 500V). Today,
KRONE can offer the TERMINATOR
™
System - capable of terminating
0.34 to 2.5mm
2
wires.
CMC enclosures designed by KRONE to maximise space savings
CJB equipped with KRONE
Instrumentation Modules and
27-Way Backmount Frames
Multicore cable drain wires terminated at top of CMC Layout of KRONE backmount frames and PVC cable
ducting in CMC
Multicore instrumentation cables entering CMC from
cable ladder
CMC wiring installation by Siemens tradesman
KRONE Products Used at LoyYangBPower Station:
Description Part Number Qty Turbine House Qty Boiler
Instrumentation Terminal Modules 6468 2 008-00 6864 2664
Side Mounting Label Holders 6462 3 118-00 6992 2704
Pair Commoning Module 6462 2 014-00 128 40
Backmount Stand-Offs 6460 3 004-01 512 160
27 Way Backmount Frames 6455 2 034-01 220 112
66 Way Backmount Frames 6450 3 009-00 128 40
15mm Label Holders 6092 2 012-06 128 40
Test Module with Test Cord 6037 2 011-01 32 10
The KRONE Advantage;
Cost Savings, Reliability and
Flexibility
It is easy to highlight the immediate
benefits that the KRONE LSA Plus
System offers; ie increased
productivity which leads to reduced
installation costs.
But the KRONE Insulation
Displacement Connection (IDC)
technique also offers long-term
benefits such as:
• Vibration resistance
• Gas tight, corrosion proof
connections
• Mistake proof system
• Test access*
• Patching*
• Circuit isolation*
• Plug-in overvoltage protection*
*Note: without the need to remove
terminated wires.
Following is a summary of savings
achieved during the construction of
the LoyYangBpower station.
All figures quoted are approximate
and are in Australian Dollars. The
costs are based on the best available
information at the time of printing.
(One KRONE terminal module is
equivalent to 20 through type screw
terminals.)
Floor Space Reduction:
Cost per m
2
(1988) $5,000
Space savings 45m
2
Cost Savings AUD $225,000
Time savings:
per 20 terminations 9 min
380,000 terminations 2,850 hrs
at $35.00 per hour $99,750
Savings AUD $99,750
Increased Long-term Reliability
and Flexibility:
Cost Savings $$$
Time savings of up to 41% are
achieved with the KRONE system.
Purchase Cost Savings:
KRONE instrum. module $10.35
20 screw terminals $15.00
Savings/20 terminations $4.65
$2.65 x 9696 modules $45,086
Savings AUD $45,086
Estimated Savings
Estimated Savings
Achieved by Using KRONE
Achieved by Using KRONE
Equipment:
Equipment:
Short-term:
Short-term:
AUD $370,000
AUD $370,000
Long-term: $$$
Long-term: $$$
Wire
wrap
Time Savings
7%
41%
Screw
type
27min
25min
16min
KRONE
LSA Plus
Advantage 11:
Reduced Installation Time
Time and motion study was
conducted by SECV to compare
KRONE LSA Plus with other
connection techniques.
The time to complete 20
terminations (incl. cable preparation)
was:
• Wire wrap 27 min
• Screw type 25 min
• KRONE LSA Plus 16 min
KRONE’s unique mounting system
reduces installation time even further
as no end clamps or end plates are
required.
Advantage 22:
Reduced Purchase Cost
The SECV found the KRONE terminal
modules to be very price competitive
when compared to screw terminals
of good quality.
Furthermore, there is no need to
purchase end plates or end clamps.
Advantage 33:
Reduced Floor Space
Customised cabinets were designed
to take full advantage of the high
density design of the KRONE
modular system.
It is estimated that the required floor
space was reduced by 45m
2
.
Advantage 44:
Increased Long-term
Reliability & Flexibility
The long-term reliability and
flexibility of the KRONE system will
continue to save the operators of Loy
Yang BPowerStation time and
money over many years.
KRONE Insulation Displacement
Connection (IDC)
The principle of the KRONE LSA-PLUS
®
contact with
the 45
O
layout:
Q Gas-tight, self cleaning contact
Q Fast, simple installation
Q Constant contact reliability for 15 years or more
Q Worldwide use in telecommunications, data and
electrical networks
How does KRONE LSA-PLUS
®
work?
It’s simple!
The multi-function LSA-PLUS
®
based insertion tool
presses the wire between the flexible jaws of the
contact slot. The edges of the slot cut through the
insulation and notch the conductor at two opposite and
offset points, without reducing the cross-section area of
the conductor.
Material displacement of the copper conductor and
torsional and restoring forces of the contact jaws lead to
two permanent, gas-tight contact areas.
During the insertion process, the insulation is gripped in
the plastic ribs of the LSA-PLUS
®
terminal module,
protecting the contact point against vibration and tensile
stress.
At the same time the integrated scissors cut off the
excessive wire length.
The result:
A wire is connected in one single operation; it couldn’t
be any simpler, any safer or any quicker.
KRONE (Australia) TECHNIQUE PTY. LIMITED
ACN 002 047 181
2 Hereford Street, BERKELEY VALE, NSW, 2261
Telephone: +61 (0)2 4388 4422
Facsimile: +61 (0)2 4388 4499
Toll Free Help Desk: 1800 801 298
Internet Address: www.krone.com.au
Email: kronehlp@krone.com.au
Quality Certified to ISO 9001
PC5176
KRONE’s Terminal Module Range
Cu Conductor Cross Sectional
AWG
Max
Dia (mm) Area (mm
2
) Voltage
• Voice & Data Modules 0.4 - 0.8 0.12 - 0.5 26 - 21 150V
• Profil Series 2 Modules 0.65 - 0.9 0.33 - 0.64 22 - 20 150V
(Instrumentation Modules)
• Profil Interface Modules (in) 0.4 - 0.8 0.12 - 0.5 26 - 21 150V
(out) 0.65 - 0.9 0.33 - 0.64 22 - 20 150V
• Terminator 1.5 Modules 0.65 - 1.4 0.34 - 1.5 22 - 16 500V
• Terminator 2.5 Modules 1.2 - 1.8 1.0 - 2.5 16 - 14 500V
• Terminator Interface Modules (in) 0.65 - 1.4 0.34 - 1.5 22 - 16 500V
(out) 1.2 - 1.8 1.0 - 2.5 16 - 14 500V
Additional Information
. replaced by slotted
PVC cable duct.
The contract specified 42 CMC’s to
be installed:
• turbine house cabling 32
• boiler cabling 10
Cable Junction Boxes
Cable. from 2-2 0
pairs (usually 0.5mm
2
, 7/0.30).
The contract specified 176 CJB’s to
be installed in Loy Yang B.
• turbine house cabling 120
• boiler cabling