GITARU UNIT 1 PLC UPGRADE USING KENGEN INTERNAL RESOURCES Presented by: Samuel M. Waithaka 2018 G2G INNOVATION SEMINAR, PRIDE INN SPA & RESORT 18TH JUNE - 22ND JUNE 2018

SAMUEL M. WAITHAKA Electrical Engineer II – PIC, Technical Services, Eastern Hydros GITARU UNIT 1 PLC UPGRADE USING KENGEN INTERNAL RESOURCES Qualifications: BSc. Electrical and Electronic Engineering Graduate Member EBK Graduate Member IEK Responsibilities: Ensure optimum machine availability and system maintenance in Protection, Instrumentation and Control Key milestones/achievements include: Kamburu MIV and Generator Rehabilitation Works - Ongoing Gitaru PLC upgrade Tana DCS upgrade works Kamburu Rehabilitation – Excitation & Protection

Presentation Outline INTRODUCTION HISTORY BACKGROUND OF THE STATION CHALLENGES TECHNICAL SOLUTION BY KENGEN COST BENEFIT ANALYSIS INNOVATION RECOMMENDATIONS

JOH-KGN001-20071212-JvW-X1 INTRODUCTION GITARU POWER STATION Gitaru is the 3rd Hydro Power Station in the Tana cascade comprised of three hydro generating units with a total capacity of 225MW- Largest Hydro Plant. Unit 1 was installed and commissioned in 1999 and has a generating capacity of 80MW Priority 1 generating unit and the area

PROJECT SCADA INTRODUCTION ANALOGUE TO DIGITAL REVOLUTION JOH-KGN001-20071212-JvW-X1 INTRODUCTION PROJECT SCADA ANALOGUE TO DIGITAL REVOLUTION

INTRODUCTION SCADA HISTORY CONTRACTOR: IBERDROLA Co., SPAIN Implementation between 2006 – 2010 in all major Hydros KENGEN TRAINED STAFF : 5

INTRODUCTION CONTROL DESK OPERATOR STATION JOH-KGN001-20071212-JvW-X1 INTRODUCTION CONTROL DESK OPERATOR STATION Introduction of automation in Eastern Hydro and Turkwel Power Stations

INTRODUCTION Definition of Terms PLC Programmable Logic Controller JOH-KGN001-20071212-JvW-X1 INTRODUCTION PLC - Industrial computer control& monitor process values HMI – display connected to the PLC to show process values Definition of Terms PLC Programmable Logic Controller Industrial computer used to monitor and control process values HMI – Human Machine Interface Device/ screen that shows real time process values

INTRODUCTION Definition of Terms JOH-KGN001-20071212-JvW-X1 INTRODUCTION I/O cards – used as interface between field devices and PLC Definition of Terms SCADA – Supervisory Control and Data Acquisition System of both hardware, software and an expansive communication network used to control industrial systems locally or from a remote location.

I/O cards – used as interface between field devices and PLC JOH-KGN001-20071212-JvW-X1 I/O cards – used as interface between field devices and PLC

HISTORY SYNOPSIS Gitaru Unit 1 PLC : SIEMENS S5 PLC JOH-KGN001-20071212-JvW-X1 HISTORY Gitaru Unit 1 was the only machine with a different PLC in the entire 7 forks cascade During SCADA phase 1, a PLC was introduced as interface to this PLC. SYNOPSIS Gitaru Unit 1 PLC : SIEMENS S5 PLC 18yrs+ of service with the controller No manual control

GITARU UNIT 1 PLC ARCHITECTURE HISTORY GITARU UNIT 1 PLC ARCHITECTURE HMI 2 PLCs for redundant configuration S5 PLCs I/O CARDS INPUTS Temperature Pressure Voltage Field Devices OUTPUTS Start Pump Close Breaker Start Governor

GITARU UNIT 1 PLC UPGRADE WHY????

PROBLEM STATEMENT 1. Operational Challenges Intermittent unexplained machine trips 86D – PLC interrogation challenges. This resulted in: Customer reservation/lack of confidence on machine reliability and availability Loss of revenue to the company Too many points of failure – many interfaces used in the control system

LOSS OF REVENUE DUE TO THE FREQUENT TRIPS (source: CBM Monthly Report for Gitaru from Kamburu Dispatch) Period Breakdown Restored Duration Loss of Revenue 1 Jan-12 19:16 19:49 0:33 51,264.87 2 Feb-12 6:59 7:39 0:40 62,139.24 3 17:07 18:12 1:05 100,976.27 4 Apr-11 9:00 9:43 0:43 66,799.68 5 May-11 8:24 11:25 3:01 281,180.06 6 21:16 23:44 2:28 229,915.19 7 5:43 12:54 7:11 669,550.31 8 Aug-11 19:09 19:52 9 20:25 21:00 0:35 54,371.84 10 8:12 13:50 5:38 525,076.58 11 18:52 19:51 0:59 91,655.38 12 Sep-11 12:31 12:57 0:26 40,390.51 13 19:18 19:30 0:12 18,641.77 14 18:29 18:40 0:11 17,088.29 15 Dec-11 19:20 0:32 49,711.39 16 Feb-10 11:52 15:15 3:23 315,356.64   TOTAL MINUTES 1,700.00 TOTAL IN KES 2,640,917.70

LOSS OF REVENUE: KES 2,640,917.70

PROBLEM STATEMENT 2. Hardware Challenges No support from the manufacturer – Outdated technology Black box Tools to interrogate the system outdated - PG Programma laptop the size of a modern day travel bag

PROBLEM STATEMENT Last Force Majeure JOH-KGN001-20071212-JvW-X1 PROBLEM STATEMENT Last Force Majeure On the 25th May 2017, machine out for 46hrs: Loss of Power Supply Loss of interface PLC program, Standby PLC failure – Error status CPU battery spares unavailable

WAY FORWARD…

TECHNICAL SOLUTION BY 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 Outage granted on 05th June, 2017 Teams involved: Technical Services Engineers ICT Department

TECHNICAL SOLUTION BY KENGEN PROJECT EXECUTION TEAM Team lead John Muoka : Senior Engineer TEAM MEMBERS Moses Mungai Bernard Njenga Bernard Nyaga Andrew Onchagwa Nahashon Chelugo Karinaah Luvango Martha Kihara Anthony Chesang Francis Kiarie Enoch Biamah George Ofula Margaret Omusundi Paul Kiambuthi Denis Muya Samuel Waithaka

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 in each section incorporated to participate in the project. Team constituted staff members from:- Tana Kamburu Gitaru Stima Plaza Turkwel Sondu

TECHNICAL SOLUTION BY KENGEN Roles Technical Services Engineers: Engineering and design of the control system as per the machine requirements Installation, testing and commissioning of the control system Updating of the machine control documentation/ drawings

TECHNICAL SOLUTION BY KENGEN Roles ICT Department: Network configuration and integration of the Gitaru U1 controls to SCADA network Optimization of the network / communication interfaces Update of the operator work stations user interface and SCADA database servers

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

COST BENEFIT ANALYSIS APPROACH 1 USE OF A CONTRACTOR

COST BENEFIT ANALYSIS CASE STUDY: TANA UNIT 1 PLC RE-ENGINEERING Tana Power Station DCS upgrade - Iberdrola Co., Spain Services rendered:- Engineering service Commissioning service Factory Training

COST BENEFIT ANALYSIS CASE STUDY: TANA U1 PLC 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 EUROS €128,546.60

COST BENEFIT ANALYSIS TOTAL KES18,623,029.78 JOH-KGN001-20071212-JvW-X1 COST BENEFIT ANALYSIS CASE STUDY: TANA UNIT 1 PLC WORKS Costs incurred DESCRIPTION COST (KES) 1 Administrative costs (Allowances) by KenGen 2,753,952.00 2 Engineering, Commissioning & Training Services by Contractor 15,869,077.80 TOTAL KES18,623,029.78

USE OF INTERNAL CAPACITY JOH-KGN001-20071212-JvW-X1 COST BENEFIT ANALYSIS APPROACH 2 USE OF INTERNAL CAPACITY

COST BENEFIT ANALYSIS TOTAL KES 6,918,800.00 JOH-KGN001-20071212-JvW-X1 COST BENEFIT ANALYSIS CASE STUDY: GITARU UNIT 1 PLC UPGRADE Costs incurred DESCRIPTION COST (KES) 1 Administrative costs (Variable allowances ) 4,518,800.00 2 Estimated salaries (12 pple for 30 days) 2,400,000.00 TOTAL KES 6,918,800.00

JOH-KGN001-20071212-JvW-X1 COST BENEFIT ANALYSIS CASE STUDY: PROJECT COST COMPARISON REALIZED PROJECT SAVING = KES 10,300,029.78 GITARU U1 PLC UPGRADE TANA U1 PLC WORKS   DESCRIPTION COST (KES) 1 Engineering & Commissioning -Administrative costs by KenGen 6,918,800.00 KenGen Administrative costs (Allowances) 2,753,952.00 2 Contractual cost (Engineering, Commissioning & Training Services) 15,869,077.78 TOTAL KES 6,918,800.00 KES 18,623,029.78

COST BENEFIT ANALYSIS BENEFITS JOH-KGN001-20071212-JvW-X1 COST BENEFIT ANALYSIS BENEFITS Implementation of the project by KenGen own internal capacity resulted in a saving of KES 11,704,229.78 Shorter execution time and reduced outage period Capacity building/knowledge transfer

JOH-KGN001-20071212-JvW-X1 INNOVATION Engineering, Design and Installation and Commissioning done by KenGen own staff Both PLC programming and the actual works were done concurrently

RECOMMENDATIONS 1. Project design & execution: 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 review Installation Commissioning 2. Capacity building Nominated staff who attend specialized trainings to carry out internal trainings to transfer/share knowledge.

JOH-KGN001-20071212-JvW-X1 RECOMMENDATIONS 3. Future Projects Projects of this nature should be done in partnership with the contractor to enhance knowledge transfer. This shall boost employee confidence in the system and encourage innovative practices and save on costs across the company.

JOH-KGN001-20071212-JvW-X1 RECOMMENDATIONS 4. New Revenue Streams: As specialty in PLC and SCADA design is honed, KenGen can offer consultancy services and solutions to other industry players. 5. System Review: Installed system to be reviewed after a period to check on the system performance, availability of critical spares and technological advancements

DECOMISSIONED PLC SCADA INTERFACE PLC

Teams at Work

Teams at Work

Old PLC Configuration

New PLC Configuration PLC Rack Terminal blocks Input/ output cards

Operations Director Eng Solomon Kariuki addressing the Team