Tài liệu Case Study - Loy yang B Power Station pptx

LOY YANG B POWER STATIONMorwell, Victoria, Australia A Case Study on KRONE Industrial Wiring Products Scope: Application of KRONE terminal modules within the Instrumentation and Control

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 0.9mm2cable) 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

0.5mm2(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 0.5mm2, 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 2.5mm2(7/0.67) cable is used for voltage drop protection The IJB is normally connected to the CJB via multicore instrumentation cables (usually 0.5mm2, 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 2.5mm2 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 2.5mm2wires

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:

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 m2(1988) $5,000 Space savings .45m2

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

Achieved by Using KRONE

Equipment:

Short-term:

AUD $370,000

Long-term: $$$

Wire wrap

Time Savings 7%

41%

Screw type

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 45m2

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:

QGas-tight, self cleaning contact

QFast, simple installation

QConstant contact reliability for 15 years or more

QWorldwide 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

• 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 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