Transforming Power: ABB’s Cutting-Edge Upgrade Boosts Efficiency at Singapore’s KMC Power Plant

In a bold move to enhance the efficiency and reliability of one of Singapore’s key power plants, ABB is set to revolutionize the gas turbine control system at the 1,300 MW Keppel Merlimau Cogen (KMC) combined cycle gas turbine on Jurong Island. This landmark upgrade promises to not only bolster the plant’s operational prowess but also align with Singapore’s ambitious energy goals, steering the nation closer to its net zero emissions target by 2050.

Revamping Control Systems: A New Era for KMC

ABB’s commissioned upgrade involves replacing the existing Egatrol 8 turbine control system with the advanced Egatrol X. This state-of-the-art system is built on the robust ABB Ability™ System 800xA® flagship distributed control system (DCS) and the modern AC800M portfolio. The seamless transfer of full functionality from the old system to the new one ensures minimal downtime and a swift installation process, showcasing ABB’s commitment to efficiency and reliability.

“Transferring full functionality from the existing application to the updated solution allows the customer to avoid downtime and install the control system in the shortest possible time,” explained Erik Holsten, President of ABB Energy Industries. The upgrade strategy involves a flexible, customized approach, replacing older components as needed, thus preventing unnecessary downtime and avoiding the high costs associated with operational loss.

Seamless Integration: A Smooth Transition

The heart of this upgrade lies in ABB’s innovative in-house software code conversion process. This approach eliminates the need for time-consuming adjustments of system parameters, ensuring a smooth transition. The user interface, based on the intuitive System 800xA, requires only minor tweaks, significantly reducing the need for operator retraining.

The hardware design, featuring ABB’s latest I/O evolution kit, cuts down commissioning time and eliminates the risk of re-wiring errors, further enhancing the efficiency and reliability of the plant’s operations. This meticulous attention to detail exemplifies ABB’s expertise in delivering tailored solutions that meet the unique needs of their clients.

Driving Singapore’s Energy Transition

Singapore is on a determined path to achieve net zero emissions by 2050, with the government actively promoting energy efficiency and emissions reduction through various grants and investments in low-carbon technologies. Currently, power generation accounts for 40 percent of the nation’s carbon dioxide emissions. By diversifying its energy supply across four key areas—solar, regional power grids, emerging low-carbon alternatives including hydrogen, and natural gas—Singapore aims to significantly reduce its carbon footprint.

The KMC project stands as a testament to how ABB’s advanced technologies can enhance energy and carbon efficiency in gas power generation. This initiative not only ensures a stable and reliable energy supply but also supports the integration of renewable energy sources into the grid, furthering the shared goals of the global energy transition.

Expert Insights: ABB’s Commitment to Innovation

“As a global leader in the DCS market, ABB has both the expertise and technology to deliver flexible, customized upgrade installations in the fastest and safest way available,” Holsten emphasized. “Turbines sit at the heart of a power plant, and our gas turbine control systems have been helping utilities provide electricity to households across the world in the most efficient and sustainable way possible.”

Miguel Benito, Assistant Managing Director, Technical and Operations, Power & Renewables, Infrastructure at Keppel, echoed this sentiment. “We are pleased to renew the longstanding partnership between Keppel and ABB with the latest turbine upgrade project. Leveraging ABB’s strong domain knowledge, we are confident that KMC will experience a smooth and seamless migration to the updated system, which is critical to our productivity and ability to provide reliable power supply to the grid.”

A Step Towards a Sustainable Future

ABB’s upgrade of the gas turbine control system at KMC is more than just a technical enhancement; it’s a strategic move towards a more sustainable and efficient energy future for Singapore. By harnessing advanced technology and innovative solutions, ABB is helping to drive the nation’s energy transition, ensuring a reliable power supply while reducing carbon emissions. This project underscores the critical role of technological innovation in achieving global sustainability goals.

Source: ABB