1. 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

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

3. 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.

4. 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

5. 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

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

7. INTRODUCTION
PLC and EchoLink Interfaces
HMI

8. 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.

9. 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

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

11. 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Outdated cards and technology
Tools to interrogate the system outdated - PG Programma laptop the size of a modern day travel bag

12. 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

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

14. LOSS OF REVENUE DUE TO THE FREQUENT TRIPS

15. 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

16. WAY FORWARD…

17. 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

18. 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

19. 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
Outage requested and granted on 05th June, 2017
Teams involved:
Technical Services Engineers
ICT Department

20. 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

21. 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

22. TECHNICAL SOLUTION BY KENGEN
JOH-KGN 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

23. 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

24. 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

25. FINANCIAL IMPLICATIONS
CASE STUDY: TANA DCS RE-ENGINEERING WORKS
COSTS: Unit 1 Price Schedule
*1 EURO = KES
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

26. FINANCIAL IMPLICATIONS
JOH-KGN 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

27. FINANCIAL IMPLICATIONS
JOH-KGN 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

28. FINANCIAL IMPLICATIONS
JOH-KGN 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

29. RECOMMENDATIONS Design development Installation Commissioning
JOH-KGN 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.

30. RECOMMENDATIONS 3. Future Projects 4. Systems Audit
JOH-KGN 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

31. Teams at Work

32. Teams at Work

33. Teams at Work

34. Teams at Work

35. Old PLC Configuration

36. New PLC Configuration
PLC Rack
Terminal blocks
Input/
output cards

37. Operations Director and Area Manager Addressing the Team

38. VOTE OF THANKS
ENTIRE MANAGEMENT TEAM
WORKING TEAMS

39. THANK YOU