1. 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

2. 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

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

4. JOH-KGN 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

5. PROJECT SCADA INTRODUCTION ANALOGUE TO DIGITAL REVOLUTION
JOH-KGN JvW-X1
INTRODUCTION
PROJECT SCADA
ANALOGUE TO DIGITAL REVOLUTION

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

7. INTRODUCTION CONTROL DESK OPERATOR STATION
JOH-KGN JvW-X1
INTRODUCTION
CONTROL DESK
OPERATOR STATION
Introduction of automation in Eastern Hydro
and Turkwel Power Stations

8. INTRODUCTION Definition of Terms PLC Programmable Logic Controller
JOH-KGN 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

9. INTRODUCTION Definition of Terms
JOH-KGN 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.

10. I/O cards – used as interface between field devices and PLC
JOH-KGN JvW-X1
I/O cards – used as interface between field devices and PLC

11. HISTORY SYNOPSIS Gitaru Unit 1 PLC : SIEMENS S5 PLC
JOH-KGN 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

12. 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

13. GITARU UNIT 1 PLC UPGRADE
WHY????

14. 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

15. 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

16. LOSS OF REVENUE: KES 2,640,917.70

17. 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

18. PROBLEM STATEMENT Last Force Majeure
JOH-KGN 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

19. WAY FORWARD…

20. 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

21. 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

22. TECHNICAL SOLUTION BY KENGEN
PROJECT EXECUTION
Outage granted on 05th June, 2017
Teams involved:
Technical Services Engineers
ICT Department

23. 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

24. TECHNICAL SOLUTION BY KENGEN
JOH-KGN 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

25. 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

26. 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

27. 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

28. COST BENEFIT ANALYSIS
APPROACH 1
USE OF A CONTRACTOR

29. 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

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

31. COST BENEFIT ANALYSIS TOTAL KES18,623,029.78
JOH-KGN 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

32. USE OF INTERNAL CAPACITY
JOH-KGN JvW-X1
COST BENEFIT ANALYSIS
APPROACH 2
USE OF INTERNAL CAPACITY

33. COST BENEFIT ANALYSIS TOTAL KES 6,918,800.00
JOH-KGN 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

34. JOH-KGN 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

35. COST BENEFIT ANALYSIS BENEFITS
JOH-KGN 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

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

37. RECOMMENDATIONS 1. Project design & execution:
JOH-KGN 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.

38. JOH-KGN 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.

39. JOH-KGN 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

40. DECOMISSIONED PLC
SCADA INTERFACE PLC

41. Teams at Work

42. Teams at Work

43. Old PLC Configuration

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

45. Operations Director Eng Solomon Kariuki addressing the Team