Capturando la energía del sol, soluciones de energía y automatización para plantas solares

ABB Ltd.  Business Unit Power Generation  P.O. Box 8131  8050 Zurich, Switzerland  Phone:   +41 (0) 43 317-5380  Fax:   +41 (0) 43 317-5382  www.abb.com/powergeneration © C o py ri g h t 20 0 9  A B B . A ll r ig h ts  r e s e rv e d . Contact us

Capturing the power of the sun  Power and automation solutions forsolar plants

2  Capturing the power of the sun

Capturing the power of the sun  15

14  Customer benefits | Capturing the power of the sun Photovoltaic plants   - Complete solution from a single supplier   - Optimized modules for each stage of the process   - Produces more power, more efficiently   - Unique ABB process experience and know-how   - All power and automation products and systems          made by ABB. Thermosolar plants   - Complete power and automation solution from one supplier   - Unrivalled process expertise from CSP pioneer   - Large installed base of successfully completed projects   - Rapid project completion in compliance with international  and local standards   - All power and automation products and systems  manufactured by ABB. Customer benefits

Capturing the power of the sun  3   Local expertise and global presence ABB serves its power generation customers with a global net-work of dedicated power generation centers and strong local expertise in all major markets of the world.

4  Power and automation solutions for solar plants | Capturing the power of the sun Power and automation solutions for solar plants Clean, inexhaustible, emissions-free energy The earth absorbs more solar energy in one hour than the  whole world uses in a year.  Solar energy is clean, inexhaustible, safe and even when  converted into electricity in solar power plants, completely  emissions-free. For every kilowatt-hour of solar power  generated, as much as 600 grams less carbon dioxide  (CO 2 ) will pollute the planet. Translated into a 50 megawatt  (MW) solar power plant, the savings in CO 2  emissions are  considerable. The world wants more solar power The world needs more solar power and the world wants  more solar power. Governments are encouraging it and  some, like Spain, Germany, France and Italy are providing  incentives with preferred feed-in tariffs. The demand is there,  the market is growing and the technologies are in place and  evolving.  The question facing utilities, developers and EPCs alike is:  How best to capture that endless stream of emissions-free  heat and light, and which solutions provider should they  chose to help turn that energy into profitable, reliable  electric power?

Capturing the power of the sun | Helping our customers achieve success  13 Rapid delivery and exceptional performance Totana PV plant, Spain Capacity: 1 MW Location: Murcia, Spain Completion: September 2008 Solar technology: Photovoltaic Customer: Global Capital Finance ABB’s scope of supply: Complete solar plant solution from  design to commissioning ABB designed, delivered and commissioned the entire  solution in just four months. The plant has an exceptionally high performance ratio of 80  percent, five percent higher than the accepted  industry standard. High-performance solution for prototype utility-scale  CSP plant eSolar, United States Capacity: 5 MW Location: California, USA Completion: Early 2009 Solar technology: Power tower Customer: eSolar ABB’s scope of supply: Design, engineering and  implementation of plant control system including supervisory  control of steam turbine and interface to patented eSolar  heliostat farm control system. ABB also supplied a facet control solution that monitors  and evenly distributes the solar light reflected by each of  the farm’s 24,000 dual-axis heliostats to maximize the  performance and operating life of the two thermal receivers. 1 Totana PV plant, Spain  |  2  eSolar, United States 1 2

12  Helping our customers achieve success | Capturing the power of the sun Helping our customers achieve success Europe’s largest solar energy plants Andasol 1&2, Spain Capacity: 2 x 50 MW Location: Andalusia, Spain Completion: Andasol 1 in November 2008, Andasol 2 in 2009 Solar technology: Parabolic trough Customer: ACS Cobra and SENER ABB’s scope of supply: Complete power block automation  solution, extensive power solution Five more plants are planned for the site to give a total  generating capacity of 350 MW. Extresol 1&2, Spain Capacity: 2 x 50 MW Location: Extremadura, Spain Completion: Extresol 1 in 2009, Extresol 2 in 2010 Solar technology: Parabolic trough Customer: ACS Cobra and SENER ABB’s scope of supply: Complete power automation solution  for the solar field and power block. One additional plant is  planned for the site to give a total generating capacity of 150 MW. ACS Cobra and SENER are also planning to build two 50 MW  plants in La Mancha using the same technology. This picture belongs to ACS Extresol power plant builded by  Cobra and Sener. 1 On-site inspection  |  2  Extresol, Spain 1 2

Capturing the power of the sun | Complete solar power solutions from ABB  5   Pioneering market and technology leader ABB has been a leading force in the solar power industry  since the early 1990s when we developed an automation  platform for the world’s first test facility for concentrating  solar power technologies at the Plataforma Solar de Almería  (PSA) in Spain. Since then we have been involved at a pioneering stage in  just about every type of photovoltaic (PV) and concentrating  solar power (CSP) technology developed, be it in Europe,  North America, Australia, North Africa or the Middle East.  This has given us a unique expertise in how best to capture,  control and store solar energy and efficiently convert it into  reliable electricity, ready for transfer into the local grid. ABB is also at the forefront in developing smart grid solutions  that integrate centralized and distributed power generation  into a single optimized network with multi-directional power  flows and real-time grid monitoring and market mechanisms. Photovoltaic power plants ABB’s solutions for PV power plants are designed to  maximize plant performance and provide owners with a rapid  return on investment and long plant operating life. Our scope of supply covers the entire project from site and  project assessment to plant design, engineering, installation,  commissioning, service and maintenance. It includes all  plant equipment and systems. With the exception of the  trackers, each solution component is designed, engineered  and manufactured by ABB specifically for PV solar power  applications.  ABB’s concept is unique – standard, pre-tested and  containerized modules of optimized plant components,  ready for installation anywhere in the world.  Thermosolar plants ABB is the world’s leading supplier of power and automation  solutions for the new generation of large-scale concentrating  solar power plants.  Our scope of supply embraces the whole plant and includes  instrumentation, control systems and electrical equipment  for each stage of the process, including electrical balance  of plant for the power block and connection to the high  voltage grid. Most importantly, ABB brings unrivalled process  expertise in the demands and requirements of the solar  field (arrays, heat transfer, thermal storage tanks) and of  converting the energy into grid-quality electric power. 100 years in power generation ABB has one of the largest installed bases of power plant  equipment in the world. Our system and process expertise in  automation and electrical balance of plant is unmatched and  covers all types of power generation – fossil-fired, nuclear,  waste-to-energy, combined cycle, hydro, wind, biomass and  solar.  ABB supports its power generation customers – who include  all the leading EPCs and OEMs – with strong local expertise  and extensive global presence. Our hallmarks of excellence  are rapid project delivery times and better plant performance. Complete solar power solutions from ABB

6  Photovoltaic plants | Capturing the power of the sun Photovoltaic plants One partner, one solution ABB has developed a standard modular concept for all PV  technologies and for all markets. It is our “one partner,  one solution” answer to the needs of customers operating in the global PV market. Each part of the solution – trackers, inverters, transformers,  control system, etc – is delivered in pre-tested, containerized  1 MW modules for scalability, cost efficiency and rapid  installation. Whether the plant has a capacity of 1 MW or  100 MW, the modules are easy to integrate and the solution  is repeatable at any site and in any country. ABB, in partnership with contracted manufacturers, offers  a complete range of solar trackers – of all types and all  materials. All other products and systems are made by ABB  and are designed for the special requirements of PV plants  and the demands of a high-performance modular solution.  Optimization – the key to productivity Optimization is a prime differentiator in the ABB solution.  It enables the plant to achieve the highest levels of power  delivery and energy efficiency.  Each ABB module is engineered for the latest generation of  solar applications and includes innovations like a uniquely  efficient automatic switching system and highly accurate  and robust controllers that enable the trackers to harness  more energy from the sun. The result is a standard modular  solution that is more productive, more efficient and more  reliable than any other on the market. Getting it right from the start ABB offers its customers a number of unique tools to  determine the optimal solution for any given site and any  given project.  Based on powerful ABB algorithms, these tools include an  automatic PV power calculation assistant that calculates  the optimal layout and generating capacity for a site, an  automatic budget calculation tool that computes the cost and  revenues of the project by taking into account all conceivable  variables, and an automatic return on investment tool that  calculates the payback time of the proposed investment.  Together, these tools enable the customer to get the project  right from the start and to know what lies ahead in the way of  costs, revenues and returns.

Capturing the power of the sun | Thermosolar plants  11 Thermal storage doubles productivity Andasol 1&2 use an innovative method for storing thermal  energy. Surplus energy captured during the day is stored  overnight in two large tanks, each of which contains  28,000 tons of molten salt. Together they almost double  the operating time and productivity of the plant by some  3,500 hours a year, enabling the turbines to generate power  during the night or on days when the sun is not shining. An  ABB control system controls the tanks and ensures that  the molten salt is kept precisely at the correct temperature  and within critical process parameters. If not, the salt will  crystallize and the contents, tanks and process equipment  be destroyed. Controlling and energizing the power plant As one of the world’s leading suppliers of electrical balance  of plant, ABB provides complete solutions in instrumentation,  control systems and electrical equipment to automate and  energize the power plant. An ABB System 800xA extended  automation system integrates the entire facility – solar field,  thermal storage tanks, power plant and grid  connection – into a single automation and information  management system. Grid connection and IEC 61850 substations The power produced by the thermosolar plant is transferred  to the power grid at the required voltage via ABB  substations – transformers, switchgear, circuit breakers,  protection and control equipment – to ensure maximum  reliability. For customers who require IEC 61850 substations,  ABB was an initiator of both the international standard and  the enabling technologies, and has conducted more than  400 installations to date. Modular standardized solutions for rapid delivery ABB provides modular standardized electrical and  control solutions for fast-track projects. These compact,  containerized solutions are designed and pre-tested for rapid  delivery and fast installation. Service and maintenance ABB offers a broad range of service and life-cycle support  options from preventive maintenance to 24/7 support, remote  monitoring and plant optimization.

10  Thermosolar plants | Capturing the power of the sun Thermosolar plants Controlling complex CSP processes Maximum energy from the sun A parabolic trough solar field for a 50 MW plant is enormous.  It consists of 624 troughs with more than 510,000 square  meters of collector surface, dispersed over 190 hectares in  156 loops of four troughs per loop.  A patented ABB programmable logic controller cabinet with  relays and low voltage switchgear - one cabinet for each  trough - enables the collectors to capture maximum energy  from the sun with minimum error. At Extresol, there are 1,248  cabinets. Exceptionally robust, the cabinets are designed to  withstand extreme environments of intense heat and cold,  as well as dust, erosion and the mechanical stress caused  by the collector moving every few seconds as it accurately  tracks the progress of the sun. Delivering the energy from the field to the turbines The concentrated energy captured by the collectors is  absorbed by heat transfer fluid (usually oil) flowing through  tubes in the solar field. ABB instrumentation and control  systems ensure that the fluid is kept within the required  temperature parameters, which can be as high as 400  degrees Celsius. The fluid is pumped to the power block,  passed through a heat exchanger, where water is heated  and steam produced to power the turbines and generate  electricity. The fluid is then returned to the solar field where  the process begins again. ABB provides complete power and automation packages  (consisting entirely of ABB products and systems) for all  the main concentrating solar power technologies –  parabolic trough, power towers, integrated solar  combined cycle, heliostat solar concentrators, Stirling  solar dish systems, combined solar biomass and others. These technologies are highly complex. They produce  large amounts of power from solar fields covering  hundreds or even thousands of dishes, troughs or  collectors spread out over hundreds of hectares in  challenging conditions of heat, cold, dust and  mechanical stress. Controlling the process and capturing maximum volumes  of energy from the sun requires knowledge, experience  and expertise. None more so than the latest generation  of parabolic trough thermosolar plants in Spain. 50 MW parabolic trough thermosolar plant A typical parabolic trough thermosolar unit produces 50 MW  of power. The generating capacity of each unit is sometimes  determined by local legislation, not by technical feasibility; the  number of units at any one site is theoretically unlimited (seven  50 MW units are projected for the Andasol site in Spain).

Capturing the power of the sun | Thermosolar plants  7 Solutions at the cutting edge ABB has played a leading and pioneering role in the  development of large-scale concentrating solar power  technologies since the industry’s birth in the early 1990s.  Most recently, ABB has provided comprehensive power and  automation solutions for the two largest thermosolar power  plants in Europe – Andasol 1&2 and Extresol 1&2, each unit  of which has a generating capacity of 50 MW. ABB is also  involved in other large-scale CSP projects in Australia, the  United States, North Africa and the Middle East. From the solar field to grid connection ABB supplies complete power and automation solutions  for the entire CSP plant – from patented high-precision  programmable logic controllers for the thousands of  parabolic troughs, dishes or collectors in the solar field to  control systems for thermal storage tanks, electrical balance  of plant for the power block, and electrical equipment that  feeds the power stably and reliably into the local power grid.  Our capability extends through the entire project chain  and includes design, engineering, erection, installation,  commissioning, service and maintenance.  Unique process expertise As a pioneer in the new generation of CSP technologies, ABB has acquired unrivalled expertise in the complex  processes of thermosolar power generation.  In parabolic trough solutions, this expertise includes such  critical process stages as controlling the temperature and  viscosity of the heat transfer fluid in the solar field, keeping  the molten salt in the giant thermal storage tanks at the  correct temperature, accurately positioning the collectors  to capture maximum energy from the sun (a patented  and uniquely precise ABB technology), and synchronizing  hundreds of devices and integrating the data into the plant  automation systems. Thermosolar plants

8  Photovoltaic plants | Capturing the power of the sun Photovoltaic plants Optimized modules for each step of the process Optimized standard modules for each stage of the PV power plant process and a complete capability  in design, engineering, erection, installation and  commissioning – this is what differentiates ABB’s  solution from the alternatives.  The benefits are proven – maximum power produced at  each moment of the day (regardless of light or weather  conditions), fewer power losses at each stage of the  process, and higher revenues. Field comparisons show  that ABB optimized solutions produce more power and  have a higher performance ratio than those of  competing suppliers.   Each ABB module and the ABB products it contains are  engineered for the requirements of PV solar applications.  These compact, pre-tested 1 MW units are easy to  install, easy to integrate and highly scalable. As a result,  delivery and project completion times are faster and  investment costs are as much as 15 percent lower. Below are some of the highlights and unique benefits of  the ABB products, modules and tools that make up the  ABB solution. Advanced quotation tools ABB has developed advanced automatic quotation tools to  compare the cost and payback time of installing the various  PV alternatives at a specific site. The tools take into account  every conceivable technical and cost variable – as well  as historical meteorological data for the site – to calculate  production revenues and return on investment.  This enables ABB to help the customer select the right PV  technology and the right solution at the very start. Solar trackers ABB supplies all types of solar trackers, from conventional  fixed-structure to 1- or 2-axis panels. Trackers are  supplied by various manufacturers under contract to ABB  and are available in all types of PV material. Consortium  arrangements with manufacturers of heliostats – technologies  well-known to ABB – are also possible. Finding the right panel or tracker  ABB’s automatic PV power calculation tool compares the  performance data of different types of panels and trackers  and calculates the correct number of parallel and serial  connections required to achieve the optimal solution for the  required generating capacity. Factors like land and civil works  requirements, tracker footprint and wind resistance, motor  energy consumption, maintenance requirements and speed  of module heat evacuation are calculated for each possible  solution.

Capturing the power of the sun | Photovoltaic plants  9 Patented controller increases tracker accuracy ABB’s patented PLC, specially developed for solar trackers  and collectors, increases the accuracy of the trackers to  within 0.2 degrees of error, thereby enabling the trackers  to capture maximum energy from the sun. The PLCs  are designed to withstand the challenging conditions of  excessive heat during the day and freezing temperatures at  night, as well as high levels of mechanical stress and dust. High-efficiency inverters Inverters are supplied by various manufacturers cooperating  with ABB. Available in the 100-500 kW power range, they  achieves an exceptional Euro efficiency of at least 97.3  percent and a standby power consumption of less than 0.1  percent of the nominal power.   Unique switching system boosts efficiency A unique and patented automatic switching system,  developed by ABB for PV applications, increases efficiency  by an additional 2-4 percent – regardless of weather  conditions – by automatically connecting or disconnecting  the number of inverters in operation according to changes  in the amount of light at different times of day and during  different types of weather. Reliable and redundant transformers Whereas competitors use a single, standard oil-filled  transformer, ABB uses two low-loss dry transformers to ensure  reliability and productivity. ABB dry transformers are more  efficient at lower loads. If one dry transformer should ever fail  the reserve will take over, thereby preventing a complete plant  shutdown. ABB oil-filled transformers are available as an option. UniMix medium voltage switchgear As the world’s leading supplier of air insulated and gas  insulated switchgear, ABB has selected its UniMix series  of medium voltage switchgear for its modular PV solution.  Itself of compact modular design, UniMix is available in  an extensive range of ratings and is especially suitable for  scalable modular solutions. DC protection cabinets ABB’s standard DC protection cabinets are the most optimal  solution for DC protection.  Control system ABB’s extended automation platform, System 800xA, is one  of the world’s most widely used process control systems. With  more than 4,000 installations worldwide and numerous unique  performance-enhancing capabilities, System 800xA is ranked  number-1 in many of the most demanding process industries. Service and maintenance ABB offers a comprehensive selection of service and  maintenance alternatives including round-the-clock  remote supervision and performance-based Full Service ®   maintenance agreements.  Other key ABB deliverables Low voltage products, process instrumentation, IEC 61850  substations, communication systems, civil works, safety and  security systems.