GITARU UNIT 1 PLC UPGRADE Presented by: Samuel M. Waithaka Denis Muya John Muoka 2017 5TH COPI-EH FORUM, TANA POWER STATION 14TH NOVEMBER, 2017

Presentation Outline INTRODUCTION HISTORY BACKGROUND OF THE STATION CHALLENGES TECHNICAL SOLUTION BY KENGEN FINANCIAL IMPLICATIONS RECOMMENDATIONS

INTRODUCTION GITARU POWER STATION Gitaru is the 3rd Hydro Power Station in the Lower Tana cascade comprised of three hydro generating units with a total capacity of 225MW- Largest Hydro Plant. Unit 2 and Unit 3 were installed and commissioned between 1975 – 1978 each generating 72.5 MW Unit 1 was installed and commissioned in 1999 and has a generating capacity of 80MW through EPC contracting.

INTRODUCTION SYNOPSIS Gitaru Unit 1 was running on SIEMENS S5 PLC - 18yrs+ of service The machine has no Manual Control Panel At the onset of SCADA phase 1, another PLC was incorporated to interface the S5 PLC to the control HMI system

GITARU UNIT 1 PLC ARCHITECTURE INTRODUCTION GITARU UNIT 1 PLC ARCHITECTURE S5 PLC I/O CARDS MOMENTUM PLC HMI HMI – Human Machine Interface PLC – Programmable Logic Controller

GITARU UNIT 1 PLC ARCHITECTURE INTRODUCTION GITARU UNIT 1 PLC ARCHITECTURE S5 Siemens PLC Input/Output Cards

INTRODUCTION PLC and EchoLink Interfaces HMI

HISTORY PROJECT: SCADA PHASE I KenGen team involved with tender preparation to determine scope of works and evaluation Contract was awarded to Iberdrola Company, Spain Design review and approvals Theory and Practical training conducted at contractor factory. On site skill/knowledge transfer during/after project execution- use of tools, troubleshooting and system maintenance.

HISTORY SCADA HISTORY SCADA PHASE I : Implementation 2006 - 2010 CONTRACTOR: IBERDROLA Co., SPAIN CONSULTANT: ENG. ELUID WAMAKIMA KENGEN TRAINED STAFF : 5 TOOLS : Concept - PLC Program, PcVue - Human Machine Interface (HMI) HARDWARE :Schneider series, Modicon Quantum I/O cards

GITARU UNIT 1 PLC UPGRADE GITARU U1 PROJECT GITARU UNIT 1 PLC UPGRADE WHY????

BACKGROUND Hardware Challenges No support from the manufacturer Black box - No familiarity to the installed system by the T/S team Outdated cards and technology Tools to interrogate the system outdated - PG Programma laptop the size of a modern day travel bag

BACKGROUND Operational Challenges Too many points of failure – many interfaces used in the control system – Momentum PLC, EchoLink Some failures required PLC program restoration Intermittent unexplained machine trips - Not captured in events This resulted in:- Customer reservation/lack of confidence on machine reliability and availability Loss of revenue to the company

BACKGROUND A numerical relay introduced to isolate and identify group trips Relay Installed

LOSS OF REVENUE DUE TO THE FREQUENT TRIPS

BACKGROUND Recent breakdown 25th May 2017, machine out for 46hrs – DC failure, loss of interface PLC program, restored with 1 active PLC Translates = KES 930,000,000.00 Standby PLC failure – Error status CPU battery spares unavailable

WAY FORWARD…

TECHNICAL SOLUTION BY KENGEN KenGen Technical Services team floated a proposal 2014;- To change existing control system to a modern compact PLC that can be directly interfaced to SCADA system Automation, interface works to be carried out by KenGen Control and SCADA Engineers Proposal approved by management Single source (Direct procurement) of the equipment and tools granted

TECHNICAL SOLUTION BY KENGEN Working Teams Internal capacity was built during SCADA Phase I project in 2010 T/S Engineers and ICT department support and maintain installed control systems Skills/knowledge transfer: to new staff who joined the company - post 2010

TECHNICAL SOLUTION BY KENGEN PROJECT EXECUTION Procurement of equipment and tools – 2014 Pre outage works - signal list preparation 2014/2015 Delivery of equipment to site - 2015 Outage requested and granted on 05th June, 2017 Teams involved: Technical Services Engineers ICT Department

TECHNICAL SOLUTION BY KENGEN Roles Technical Services: Procurement: PLCs, I/O cards, interface cable, crimping tools Compilation of signal list PLC Programming - control logics Signal Functional Checks Commissioning Update drawings

TECHNICAL SOLUTION BY KENGEN Internal Resources Roles ICT Department: Set up communication infrastructure HMI design DBS/OPS updates – Gitaru/ Kamburu Plant Information (PI) Configuration HMI Function checks

TECHNICAL SOLUTION BY KENGEN JOH-KGN001-20071212-JvW-X1 TECHNICAL SOLUTION BY KENGEN Capacity Building To cater for skill/ knowledge transfer, staff from other areas were invited to participate in the project. Team constituted staff members from:- Tana Kamburu Gitaru Stima Plaza Turkwel Sondu

TECHNICAL SOLUTION BY KENGEN PROJECT EXECUTION Number of days = 30 days Program the new PLC and design the HMI interface Decommission the old PLC, I/O devices Mounting of the new PLC, I/O devices Rewiring of the new devices Download of the new PLC program Dry checks of the signals Wet test and command signals Function checks Sequence checks – Spin; Excite; Synchronize Unit Declared available

FINANCIAL IMPLICATIONS CASE STUDY: TANA DCS RE-ENGINEERING WORKS Tana Power Station DCS upgrade was done by Iberdrola, Spain PLC reprogramming and upgrade of the HMI system of all 4 generating units 1 unit was done by the contractor to completion Other 3 units done by KenGen Services rendered:- Engineering service Commissioning service Factory Training

FINANCIAL IMPLICATIONS CASE STUDY: TANA DCS RE-ENGINEERING WORKS COSTS: Unit 1 Price Schedule *1 EURO = KES 123.45 ITEM DESCRIPTION PRICE(€) 1 Engineering Services Software configuration (PLC and HMI) 57,748.86 2 Commissioning services 58,128.79 3 Employee Participation (Skills Transfer) Training at contractor factory 12,668.95 TOTAL 128,546.60

FINANCIAL IMPLICATIONS JOH-KGN001-20071212-JvW-X1 FINANCIAL IMPLICATIONS CASE STUDY: TANA DCS RE-ENGINEERING WORKS Costs incurred DESCRIPTION NO COST (KES) 1 Administrative costs (Per Diem/Callouts 2,626,000.00 2 Engineering, Commissioning & Training Services 15,869,077.80 TOTAL 18,495,077.80

FINANCIAL IMPLICATIONS JOH-KGN001-20071212-JvW-X1 FINANCIAL IMPLICATIONS CASE STUDY: GITARU UNIT 1 PLC UPGRADE Costs incurred DESCRIPTION COST (KES) 1 Administrative costs (Per Diem/Callout/Lunch/Mileage) 5,935,000.00 2 Training Component 1,138,208.00 TOTAL 7,073,208.00

FINANCIAL IMPLICATIONS JOH-KGN001-20071212-JvW-X1 FINANCIAL IMPLICATIONS CASE STUDY: PROJECT COST COMPARISON GITARU U1 PLC UPGRADE TANA DCS UPGRADE   DESCRIPTION COST (KES) 1 Engineering & Commissioning -Administrative costs (Per Diem/Callout/Lunch/Mileage) 5,935,000.00 Administrative costs (Per Diem/Callouts 2,626,000.00 2 Training component 1,138,208.00 Engineering, Commissioning & Training Services 15,869,077.80 TOTAL 7,073,208.00 18,495,077.80

RECOMMENDATIONS Design development Installation Commissioning JOH-KGN001-20071212-JvW-X1 RECOMMENDATIONS 1. Project design & execution: Experienced Engineers in operations division be involved in areas of project development and execution: Design development Installation Commissioning 2. Capacity building Nominated staff who attend specialized trainings to carry out internal trainings to transfer/share knowledge.

RECOMMENDATIONS 3. Future Projects 4. Systems Audit JOH-KGN001-20071212-JvW-X1 RECOMMENDATIONS 3. Future Projects Projects of this nature can be done in partnership with the contractor to enhance knowledge transfer. This shall boost the confidence in the system and encourage innovative practices and save on costs across the company. 4. Systems Audit Installed system to be audited over a period to check on the system performance, availability of critical spares and technological advancements

Teams at Work

Teams at Work

Teams at Work

Teams at Work

Old PLC Configuration

New PLC Configuration PLC Rack Terminal blocks Input/ output cards

Operations Director and Area Manager Addressing the Team

VOTE OF THANKS ENTIRE MANAGEMENT TEAM WORKING TEAMS

THANK YOU