Power

Systems
In recent years, the business environment surrounding Power Systems has seen much
discussion on increasingly important issues such as deregulation of the industry,
regulation of CO2 emissions, protection of the environment, and implementation
of IT. The Hitachi Group is aggressively developing technology for
the Power Systems field with the aim of achieving advanced
systems on a world-class level and improving the reliability
and cost performance of related products. This issue
introduces newly developed technology with a focus on
thermal power generation and preventive maintenance.
Power Systems

The Tokyo Electric Power Co., Inc. (TEPCO), Futtsu Thermal Power
Station Group No. 3 1,520-MW LNG-fired
Advanced Combined-cycle Power Generation Facility
The construction of the TEPCO Futtsu Group 3, Stages 3 and ronmental protection regulations in all load ranges.
4, Thermal Power Station has been successfully completed and (3) The HRSG was designed to be of minimal size (25% smaller
these units have been put into commercial operation. compared with previous unit) and large-sized modules were used
This plant is a combined-cycle power generation facility, using to minimize installation costs.
the latest 1,327°C class latest gas turbine unit along with other (4) The latest highly reliable autonomous-distributed digital-
equipment that has been selected from state-of-the-art technolo- control system “HIACS-7000” is used, resulting in auto-operation
gies and integrated to minimize environmental impact as well. and the human interface function both being enhanced.
Futtsu Group 3 was planned and developed as a major power (5) A method of house load operation was adopted to enhance
source to meet the rapidly increasing power demand of the Tokyo unassisted plant operation and to support rapid recovery of elec-
Metropolitan area. The power train equipment was supplied by tric power in case of power grid trouble.
General Electric in the U.S. and Hitachi, in addition to supplying (6) Effective cost reduction was achieved in accordance with the
all of the other equipment, including Heat Recovery Steam aim of adopting new technologies, new manufacturing methods
Generator (HRSG), also supplied and constructed all the installa- and employing well-conceived design and construction methods to
tion and commissioning work including the power train. satisfy customer requirements.
The main features of the plant are summarized as follows: Further 2 stages of Group 3 commercial operation are sched-
(1) Plant thermal efficiency is over 50% as a result of using the uled for December 2004 and June 2005, respectively. Total rated
MS9001FA++ Gas Turbine, which is an improved version of the power output of Futtsu Power Station is to be 3,520 MW after
MS9001FA that was specifically designed for application in completion of the Group 3. (Groups 1 and 2 : 1,000 MW each,
Advanced Combined-Cycle (ACC) generating systems. Group 3 : 1,520 MW)
(2) Both the enhanced dry low NOx combustor and the high effi- The construction planning for Group 4 using a 1,500°C class
ciency DeNOx facility built in the HRSG satisfied the strict envi- gas turbine is ongoing.

TEPCO Futtsu Thermal Power Station (left) and

HRSG modules just before on-base (right)
Latest ACC power generation facility, whose features
are high efficiency, high reliability, and low
construction costs.

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 Power Systems

The Okinawa Electric Power Co., Inc. Kin Thermal Power Station
220-MW Coal-fired Nos. 1 and 2 Units
Maximum power demand in Okinawa Electric Power Company
went up last year and is forecasted to continue to increase in the
future. The Kin Thermal Power Station is the largest power
station in Okinawa Pref. and it was designed and developed as a
base-load operated power station to respond to the increasing
power demand.
Main features are as follows;
(1) Steam turbine is one-flow exhaust type using a 102-cm (40
inches) last stage bucket made of titanium alloy and the HP/IP/LP
rotor is of monoblock construction.
(2) Effective cost reduction is considered, but environmental
preservation facility is fully implemented.
(3) This project is a full turnkey project constructed under the
auspices of a consortium in which Hitachi has filled the position of
“Engineering Leader” company whose function is to coordinate
all activities and ensure the project goes forward smoothly.
Reclamation of land from the Kin Bay in June 1998 was the first
step in construction work executed by KOKUBA-GUMI CO.,
LTD. The No.1 unit was put into commercial operation in
February 2002. Expected Outline of Kin Thermal Power Station
No. 2 unit is under construction and is scheduled to begin The site was prepared by reclaiming land from Kin Bay in addition to site preparation work
where the former power plant had been situated.
commercial operation in May 2003.

Development of Coal Energy Application

for Gas, Liquid and Electricity (EAGLE)
Coal is a fossil fuel that is in abundant supply all over the world.
It is a vital resource for maintaining the energy security of Japan,
because the supply is stable. However, its CO2 emission per unit of
calorific value is greater than that of other fossil fuels. It is neces-
sary to develop coal utilization technologies that are more efficient
to expand the use of coal in a fashion that meets the social demand
for a better environment. IGFC (integrated coal gasification fuel
cell combined cycle) is a combination of gasifier, which converts
coal into synthetic gas, a fuel cell, and gas turbine and steam
turbine. This system is expected to realize a much higher efficiency
compared with conventional pulverized coal-fired thermal-power
generation. Also, it is expected to be the ultimate power genera-
tion system using coal. EAGLE (coal energy application for gas
liquid and electricity) is doing researching ways to establish coal
gasification technology for application to fuel cells (with a coal-
fed 150 t/day pilot plant) aiming to implement an IGFC system.
This technology development has been directly supported by the
Japanese government and implemented under the entrustment of
the New Energy and Industrial Technology Development
Organization (NEDO).

View of EAGLE pilot plant

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Power Systems

High-voltage Direct Inverter

Applied to an Induced-draft-fan Motor
From the standpoints of carbon-dioxide-emission controls and The high-voltage direct inverter, with a rated power of 8,250
energy-resource conservation measures, energy-conservation laws kVA, adopts a multiplex transformer and a multi-step configura-
in Japan are being revised; consequently, even tougher energy- tion in order to reduce the harmonic components of the system.
saving measures are being demanded. In response to these circum- This inverter setup thus makes it possible to control the IDF
stances, one aim is to reduce the electrical power consumed by motor under variable-speed operation as opposed to the conven-
large-scale equipment at existing thermal power stations. tional constant-speed operation under a commercial power supply.
Accordingly, in collaboration with EPDC (Electric Power As a result, it is expected that the power consumption will be
Development Co., Ltd.), Hitachi, Ltd. has implemented a high- substantially reduced.
voltage direct inverter in conjunction with an existing IDF With the aim of evaluating the reliability of the inverter system,
(induced-draft fan) motor of their Takehara Thermal Power EPDC and Hitachi are currently testing it at Takehara Thermal
Station No. 3 and started its long-term testing. Power Station No. 3.

Steam Steam Generator

turbine Three-phase (6.9 kV)
commercial supply

Multiplex
Feed-water pump transformer
Boiler Chimney
Multi-phase
Fuel Feed water power supply
Multiplex transformer High-voltage direct inverter
Air
IDF Exhaust gas
Commercial A schematic and images of the high-voltage direct inverter for IDF
Forced-draft fan High-voltage operation side
inverter A multiplex transformer and a high-voltage direct inverter are installed
Motor between the commercial power supply and the IDF motor. This set-up
Three-phase variable-frequency
power supply enables variable-speed control of the IDF motor.

EGAT Ratchaburi Combined-cycle Power Plant in Thailand

The Combined-cycle Power Plant Block-1 and -2 supplied to
the Ratchaburi Power Station of the EGAT (Electricity
Generating Authority of Thailand) were put into commercial
operation in April 2002.
Hitachi, Ltd. received an order from the General Electric
International, Inc. for six generators for gas turbines, three gener-
ators for steam turbines, and six heat recovery steam generators for
Block-1 to Block-3.
The heat recovery steam generator for this project was the first
supplied for an overseas project of Hitachi.
The Block-3 will start commercial operation in August 2002.
The specifications of the major equipment supplied by Hitachi
are summarized below:
(1) Generator for gas turbine
Rated capacity : 325,000 kVA
Type : Totally enclosed, self-ventilated, forced lubricated,
H2 cooled, cylindrical rotor type, synchronous alternator
(2) Generator for steam turbine
Rated capacity : 325,000 kVA
Type : Totally enclosed, self-ventilated, forced lubricated,
H2 cooled, cylindrical rotor type, synchronous alternator
(3) Heat recovery steam generator
Steam evaporation : HP 270 t/h, IP 308 t/h, LP 27 t/h Overview of heat recovery steam generator for Ratchaburi Combined-cycle Power Plant
Type : Natural circulation, triple pressure with reheat system Block-1

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 Power Systems

H25 Type Gas Turbine Supplied to TEC (Toyo Engineering Corp.)

for the UFFL (Urea Fertilizer Factory Ltd. in Bangladesh)
Gas turbine package
Upon final assembly of the gas turbine, it was delivered to TEC
(Toyo Engineering Corporation) for installation at the UFFL
(Urea Fertilizer Factory Ltd. in Bangladesh). Commercial opera-
tion began in August 2001.
This gas turbine was ordered to replace the existing gas turbine
generator, the second export machine of the H25-type gas turbine,
which had been also developed by Hitachi, Ltd. In addition to the
gas turbine, we also supplied the control system and bypass stack.
Main Equipment Specifications:
(1) Gas turbine
Output: 18.00 MW
Gas turbine building
Type: H25 (heavy-duty type)
Fuel: natural gas
Exhaust gas: generating steam for the power station in the
existing HRSG (heat recovery steam generator)
(2) Control system
Type: digital control system
(3) Bypass stack
Uses air-operated bypass dumper to control the flow rate of
H25-type gas turbine exterior appearance
exhaust gas into the HRSG.

H25-type Gas Turbine for UFFL

It is a co-generation system that combines the H25-gas turbine and the existing HRSG.

176-MW Srisailam Pumped-storage Turbine-runner

Supplied to India
In May 1991, Hitachi received an order for six pumped-storage weld deformation and
turbine units from APGENCO (Andhra Pradesh Power stringent quality
Generation Corporation Limited) with Sumitomo Corporation control procedures
(main contractor) in Japan and BHEL (Bharat Heavy Electricals were established prior
LTD in India, one of the consortium members). The turbine to actual manufactur-
components were manufactured in both Hitachi and BHEL shops ing.
under model development and prototype design of the pump- Once all units are
turbine performed by Hitachi. The first unit was commissioned in put on line by late
April 2001. 2003, more than
In the pumped-storage power field, it is recognized that rela- 1,000 MW of electric
tively high head (over 400 meters) pumped-storage power plants power will be avail-
have been developed mainly in Japan, while on the other hand, able for the central
relatively low-head pumped-storage turbines with large discharge part of India.
have been developed in India from the view point of the more Split runner ready for shipment
economical and larger availability of water resources. The machine Due to the limits on land trans-
size of low-head and large-discharge pump-turbines is relatively portation in India, the two
large, which requires more stringent and detailed engineering in halves of the runner will be
designing, manufacturing, and quality control to ensure suitable assembled into one piece on
rigidity of such a structure. site.
The runner, one of main key components in a turbine, is 6.7 Pump-turbine ratings
meters in maximum diameter and is made of 13Cr-5Ni stainless Turbine rating Pump rating
steel. Due to the limitations of the available casting capacity and Max. turbine output 176,000 kW Max. pumping input 170,500 kW
restrictions on transportation in India, the runner is split into two Max. effective head 107.1 m Max. pumping head 106.8 m
pieces and manufactured with a fabricated structure. For this appli- Max. discharge 212 m3/s Max. flow 205 m3/s
cation, detailed FEM (finite element method) analysis of the fabri- Specific speed 166.1 m-kW Specific speed 57.8 m-m3/s
Rated speed 136.4 min–1
cated structure, the special welding technique used to minimize Type VFR-1RS

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Power Systems

Water Jet Peening — Preventive Maintenance Technology

Water jet peening (WJP) is a stress corrosion cracking (SCC) The WJP has been applied to reactor internals of three nuclear
prevention technology by reducing surface residual stress. power plants in Japan.
Initiation of SCC requires the following conditions for a certain
period of time; sensitized material, corrosive environment, and
tensile residual stress. Therefore, it is effective to reduce tensile
residual stress by WJP.
This technology uses a high-pressure water jet. However, water Water jet stream
jet kinetic energy is not enough for the purpose. Hitachi has
developed the technology using cavitation collapse energy against
the surface of the structure to make a compressive stress state. A Cavitation
high-pressure water jet, pressure of 60-70 MPa and velocity of
about 240 m/s, generates cavities from the sudden pressure drop at
the nozzle underwater. The collapse of a cavity produces impact Side plate Plastic deformation
pressure as high as 1,000 MPa at the material surface. As a result
of applying WJP, compressive stress generates on the surface since Nozzle
plastic deformation produced by WJP is elastically constrained by
the surrounding material. The best part of WJP is that it only uses
water and nothing else for the shooting material. The WJP can be
applied to even narrow places, such as nuclear reactor internals.
The photo shows the stream of the jet under water. The residual
stress is improved not only at the side plate, which the jet is
Fillet weld Bottom plate Stream of cavities
directly aimed at, but also at the bottom plate where the jet went
around corner. Because water jet stream can even go around struc-
tures, such as curved structures and small pipes. Schematic of the water jet peening (WJP)
The WJP can reduce residual tensile stress by cavitation with high-pressure water jet.

HOP — Chemical Decontamination

The high-dose rate in a maintenance area during an outage is
RPV bottom one of the major concerns of nuclear power plant operators. It
X Y results in not only the exposure of workers to radiation but also
increases costs, an outage schedule extension, etc. Hitachi has
developed a new chemical decontamination technology HOP using
hydrazine, oxalic acid and potassium permanganate for reducing
the toxicity of such a high dose rate. By using the HOP, we can
achieve a remarkable dose rate reduction with small quantities of
A RRS pump D
secondary waste and no corrosion problems.
The principle of HOP is as follows. First, some decontamina-
tion objects filled with water are heated to just below the boiling
B C point of water. In the usual case, potassium permanganate is added
for oxidation first. Then oxalic acid and hydrazine are injected to
discompose the potassium permanganate. After that, additional
8 oxalic acid and hydrazine are injected for reduction. By means of
Before decon. these agents, an oxide film including radioisotopes, such as radio-
Contact dose rate (mSv/h)

6 After decon. cobalt, is resolved. At last, the reducing agent is decomposed by

After washing using catalyst columns. The series of procedure is reiterated for the
4
necessary cycles depending on the required dose rate reduction
level.
Over the last three years, HOP was used on nine occasions in
2
Japan which included system decontaminations, full-system decont-
aminations, and tool and equipment decontaminations. The schema
0 shows samples of HOP decontamination results. The upper one
A B C D X Y
shows the vertical cross section of a reactor pressure vessel (RPV)
Plant-1 Plant-2
and the lower one shows a reactor recirculation system (RRS). The
HOP decontamination result orange marks indicate the measured points. As shown in the right
A remarkable dose-rate reduction is achieved. side graph, a remarkable dose-rate reduction was achieved.

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 Power Systems

Remotely Operated Vehicles for Underwater Use

Remotely operated vehicles (ROVs) were developed for under-
water inspections of a nuclear reactor vessel. Float Thrusters
Photos show two types of ROVs (S-Type ROV and M-Type
ROV). Both ROVs are remotely and easily operated by using a
handy controller (joy stick), and made to approach the inspection
area. The ROV can move forward, backward, up, downward,
rotate about an axis and position itself sideways using four
thrusters mounted on the body. Video
Each ROV has a video camera for visual examinations and to camera
study the surface of the structure. The camera is easily operated by
manipulating the handy controller. The camera tilt angle is from 0
S-type ROV
degrees (horizontal) to ± 90 degrees.
The ROVs have a small body, small enough to be able to access Thrusters
narrow areas (e.g., shroud support area and the bottom of the
reactor vessel). The S-Type ROV is used to inspect the suppression
chamber of the primary containment vessel. A scanner for a load-
able ultrasonic test is available as an option on the S-Type ROV.
The M-type ROV is used to inspect a reactor vessel and is the ø155 Video
camera
smaller (155 mm diameter) of the two.
Pictures of remotely operated vehicles (ROVs)
S-type ROV can perform various operations (visual test
and ultrasonic test). The M-type ROV is the smaller of M-type ROV
the two. It is small enough to access the narrow parts in
a reactor vessel.

Development of Nuclear-disaster-prevention Support Robots

Hitachi has developed nuclear-disaster-prevention support type is a working robot for disaster-prevention operations. Each
robots for the purpose of carrying out disaster-prevention robot can pass through the narrow passages in a nuclear facility,
missions in a nuclear facility. Two types of robots were developed: and can be made to approach work areas by remote control. The
the first type is an information gathering robot and the second robot with a crawler mechanism can pass up or down stairways
having pitches of up to 40 degrees, climb cross gaps and other
obstacles.
The information gathering robots transmit environmental
information in passage ways and accident areas by using a radioac-
tivity sensor, a thermal sensor, cameras, etc. The working robot
performs operations like opening doors, valve open/close opera-
tions, collecting samples of dust, water and gas, control board
operation, etc.
These robots can be operated safely and accurately in a
hazardous situation with sensor-based automated control and
A B specially designed tools. Some robots have a 3D view system with a
stereoscopic camera and a multi-view system that uses several
cameras to obtain visual information in real-time for operations
that require dexterity and precision. As to the remote control
equipment, the panel of the equipment was designed with a consid-
eration for making the arrangement similar to that of the control
board of a nuclear facility, such as switch layout and configura-
tion, and by considering the human-machine interface in an
hazardous situation to avoid errors and to reduce the amount of
tension imposed on an operator.
C D These suitability robots were determined by mockup tests
assuming nuclear accident situations. The robots demonstrated
Information gathering robots (A-C) and work robot (D) successfully their excellent capabilities in March 2001.

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Power Systems

PPS (Power Producer and Supplier) Monitoring System

By the deregulation of Transmission Open Access (TOA) in demand every 30 minutes within the wheeling service maximum
Japan, private companies can supply electric energy to their users power. And, if not, a kind of penalties and/or fines will be charged
using power transmission lines owned by power utility companies. to the PPS. On the other hand, for power utility companies it is
Those private companies are so called PPS (power producer and necessary to monitor power supply and demand values of each PPS
supplier). PPS provides generations and demands, can use power against the schedules and check the discrepancy between them
network to dispatch loads by contracting with utility company. including transmission loss.
The contract requires PPS to match electric energy supply and This PPS monitoring system satisfies above needs of power util-
ity companies. This system
gathers the power supply and
demand values of each PPS and
Load dispatching Control center Other server Other server provides current data and
On-line data
concerning power
system system (A) (B) historical 30 minutes logs in the
forms of the web-based tabular
and/or trend graph.
The PCs with D.O.R.A.
Firewall Terminal for Terminal for
Input server Input server monitoring monitoring (Hitachi’s EMS/SCADA archi-
(A) (B) tecture) are adapted to ensure
high cost performance and
PPS monitoring PPS monitoring
system reliability.
server (A) server (B)
PPS monitoring system
Structure of the PPS monitoring system
Power can be monitored and past records can
be displayed on a browser. Moreover, extra
terminals can be easily added.

Saudi Arabia, Saudi Electricity Company Western Region

JAMIA 380-kV Substation
The construction of the JAMIA 380-kV substation, in Jeddah Hitachi also supplied 380-kV outdoor surge arrester, power-
was successfully completed in May 2001G. It was energized and line carrier coupling capacitor unit, line trap, and cable protection
connected with main power grid in Jeddah as the mainstay S/S in system at this point.
Jeddah. Construction started in December 1999G near King The coordination of insulation for this hybrid transmission line
AbdulAziz University. and substation system was confirmed by surge analysis and the
Hitachi, Ltd. won and constructed this substation as a turnkey ensured insulation reliability of substation equipment by high-
project. Hitachi, in addition to supplying the 380-kV and 110-kV voltage impulse test on the 380-kV GIS on site after construction.
SF 6 gas insulated switchgear (GIS), 13.8-kV metal-clad A partial discharge sensor was installed to be used for preven-
switchgear, 500-MVA transformer, 40-MVA transformer, protec- tive maintenance after energization.
tion and control systems, power telecommunication
system, also supplied all the civil works.
All engineering, supplied equipment, and civil works
were upgraded based on proven reliability supported by
field experiences of turnkey projects in the western
region.
The layout and composition of the substation was
carefully simulated to take full advantage of GIS such as
compact sizing and harmonization with its peripheral
environment located inside the university residence zone
along a highway road.
Due to the non-availability of land for the 380-kV
overhead transmission line to run directly the substa-
tion, a separate outdoor branch connection point External view of 380-kV, 2,500-A/50-kA gas insulated switchgear at the JAMIA substation of the Saudi
located at about 6 km from the S/S area was constructed Electric Company in Saudi Arabia
for an under-ground cable connection between the The switchgear is equipped with partial-discharge sensors so that preventive maintenance can be performed
substation and the overhead transmission lines. during operation by external diagnosis.

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 Power Systems

Development of Digital Protective Device with Network Technology

A protective device for power systems detects and removes toroidal core, heightening the functions and degree of integration
abnormal phenomena to maintain operation of the power systems. with a single-chip microcomputer having a large-capacity flash
It must have high reliability to supply electric power stably. In memory, and designing the unit to consume less power.
addition, it is required to heighten the efficiency of the mainte- The third feature is the concept to eliminate human errors thor-
nance tasks to reduce the facility cost. Hitachi has put digital oughly. The software can be created by combining the basic
relays with network technology (EDR+ Series) on the market that modules and any logic circuit on a graphical user interface (GUI).
meet the above requirements. Since it is made up on the GUI, it can be checked easily by anyone
The greatest feature of these relays is that they can be remotely besides software maker. In addition, the time chart of the signals
controlled. The system information and trouble information of the can be checked with the logic simulation function. Moreover, relia-
conventional relays must be checked locally through a human bility is assured by eliminating human errors, such as mistakes in
interface (HI). Since the HI of the new relays can be controlled wiring, reading data, etc., with the automatic relay tester.
using a web browser from a remote place, such as a maintenance The development cost of the new relays was reduced by applying
base, etc., the maintenance work efficiency is heightened. conventional technologies. The basic modules of the software and
Furthermore, a web server is installed at each relay to heighten the hardware were the standard modules that required no modifica-
response. tions. For example, various existing input and output modules can
The second feature is each of the new relays is small and light- be used as they are, and high extendibility is obtained, since the
weight and all the functions are incorporated in a single unit. bus specifications are common to the new relays and existing prod-
With this feature, the overall cost is lowered by the reductions in ucts. High reliability is also obtained by using modules that have
size and power consumption and unification of facilities. The size been used in wide use for many years.
and weight were reduced by applying an analog input that uses a

GPS receiver
HI
(Browser)

CPU
Panel DI
(Main relay)

CT/VT Aux
AI DO MX
CT/VT

Power CPU
DC110 V DI/O
supply (Fault detecting relay) FDX

T.T

Digital protective device with network technology

51