Tài liệu Case Study - Loy yang B Power Station pptx

LOY YANG B POWER STATION Morwell, Victoria, Australia A Case Study on KRONE Industrial Wiring Products Scope: Application of KRONE terminal modules within the Instrumentation and Control Wiring System of Loy Yang B Power 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 Yang B power station 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 Loy Yang A power station. This prompted them to research the use of KRONE modules in the instrumentation and control system of Loy Yang 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 Yang B 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 Loy Yang B commenced in 1990 and the power station was commissioned on-line in 1994 Specifications Loy Yang B Power 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 Loy Yang 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 Loy Yang 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 Loy Yang B Power 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 Loy Yang B power 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 B Power Station 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