Description

The ABB UNITROL1020 3BHE030579R0003​is a fully digital,high-performance automatic voltage regulator(AVR)and excitation system manufactured by ABB.Designed for synchronous generators ranging from 1 MVA to over 100 MVA,this system provides precise control of generator terminal voltage and reactive power,ensuring stable and efficient operation while protecting the generator and enhancing overall power grid stability.

Application Scenarios

Consider a large paper mill with its own 50 MW cogeneration plant.The generator must supply stable power to sensitive mill drives while exporting surplus electricity to the local grid.A voltage dip on the grid,caused by a fault miles away,threatens to disrupt the mill’s production.The ABB UNITROL1020 3BHE030579R0003​is the system that prevents this.Its integrated Power System Stabilizer(PSS)function detects the incipient power oscillations and injects a damping signal into the AVR loop within milliseconds.This action modulates the generator’s field current to counteract the oscillation,keeping the mill’s internal voltage rock-solid and preventing a trip.Simultaneously,its high initial response characteristic rapidly boosts excitation to support the external grid voltage during the fault,fulfilling grid code requirements.For the plant manager,the UNITROL1020​is not just a regulator;it’s a business continuity tool that prevents costly production halts and avoids penalties from the grid operator for poor dynamic performance.

Parameter

Main Parameters

Value/Description

Product Model

ABB UNITROL1020 3BHE030579R0003

Manufacturer

ABB

Product Type

Digital Excitation System/Automatic Voltage Regulator(AVR)

Control Modes

Automatic Voltage Control(AVR),Field Current Control(FCR),Power Factor/Q Control

Voltage Regulation Accuracy

Better than±0.5%under steady-state conditions

Response Time

High initial response;reaches 95%of setpoint change in<0.1 seconds

Power System Stabilizer(PSS)

Standard,compliant with IEEE 421.5,damping grid frequency oscillations

Limiting&Protection Functions

Includes Under-Excitation Limiter(UEL),Over-Excitation Limiter(OEL),V/Hz Limiter

Field Supply

Compatible with both static(thyristor-based)and brushless(rotating diode)exciters

Communication Interfaces

Multiple serial(RS485)and Ethernet ports for integration with DCS/SCADA

Human-Machine Interface

Graphical local control panel(LCP)with color display

Redundancy Options

Available for controllers and power sections for high-availability applications

Environmental Rating

Designed for harsh environments,typically IP54 for cabinet

Technical Principles and Innovative Values

Innovation Point 1:Adaptive Control with Model-Based Tuning.Unlike fixed-gain PID controllers,the ABB UNITROL1020 3BHE030579R0003​employs sophisticated adaptive control algorithms.It can perform an online generator identification test to model the specific magnetic and electrical characteristics of the machine it controls.Using this model,the system auto-tunes its AVR and PSS parameters for optimal dynamic performance and stability margins.This means a hydro generator with long time constants and a gas turbine generator with fast response can both be optimally controlled by the same hardware platform,eliminating months of manual tuning and guesswork.

Innovation Point 2:Unified Platform with Scalable Hardware Architecture.The UNITROL1020​is built on a modular,scalable platform.The core controller,I/O modules,and power stages(thyristor bridges)are designed as building blocks.This allows the same 3BHE030579R0003​control philosophy to be applied to a small diesel genset or a large utility steam turbine by scaling the power section and adding I/O as needed.This unification drastically reduces engineering time,simplifies spare parts management,and ensures a consistent operator experience across an entire fleet of generators.

Innovation Point 3:Cybersecurity and Data Integrity for Modern Grids.Recognizing the critical nature of excitation control,the UNITROL1020​incorporates industrial cybersecurity features from the ground up.This includes role-based access control,audit trails for all parameter changes,and secure communication protocols.Its extensive data logging and sequence of events(SOE)recording capabilities,with millisecond resolution,provide an indisputable record of system behavior during disturbances.This is invaluable for forensic analysis after grid events and for demonstrating compliance with increasingly stringent grid codes and NERC CIP standards.

Application Cases and Industry Value

Case Study:Offshore Wind Farm Collector Platform.An offshore wind farm uses a large synchronous condenser(a generator running without a prime mover)on the central platform to provide dynamic voltage support and short-circuit power to the grid connection.The harsh,saline environment and the need for flawless unmanned operation demanded an exceptionally reliable excitation system.The ABB UNITROL1020 3BHE030579R0003​was selected.Its ruggedized construction resisted the corrosive atmosphere.More critically,its advanced PSS and reactive power control capabilities allowed the condenser to act as a”shock absorber”for the intermittent wind power,smoothing voltage fluctuations and improving power quality for the onshore grid.Remote diagnostics via its Ethernet interface allowed onshore engineers to monitor health and performance,predicting maintenance needs.The wind farm operator reported a significant reduction in grid compliance-related issues and credited the excitation system’s stability with enabling a higher capacity factor for the wind turbines by maintaining robust grid voltage at the point of interconnection.

Related Product Combination Solutions

ABB UNITROL 1000 Series Controllers:The broader family,including the UNITROL1020,with variants like the UNITROL1010​for smaller machines or the UNITROL1080​for the largest generators.

ABB Thyristor Power Packs(TPP):The matched,liquid-or air-cooled thyristor bridges that convert AC to controlled DC under the command of the UNITROL1020​AVR for static excitation systems.

ABB EXCITATION Transformer:The dedicated transformer that provides the AC supply to the thyristor power pack,sized and specified for the specific UNITROL1020​application.

ABB Generator Protection Relays(e.g.,REG670):Complementary devices that provide comprehensive fault protection(differential,stator ground)while receiving key signals from and coordinating with the UNITROL1020​limiter functions.

ABB Ability™System 800xA:The enterprise DCS into which the UNITROL1020​can be seamlessly integrated,allowing plant-wide visualization,historian logging,and advanced control strategies.

ABB Field Discharge Resistors&Circuit Breakers:The associated switching and protection equipment for the generator field winding,controlled by interlocks from the UNITROL1020.

ABB Service Tool(Asset Suite Quick Builder):The dedicated engineering and maintenance software for configuration,commissioning,monitoring,and diagnostics of the UNITROL1020​system.

Installation,Maintenance,and Full-Cycle Support

Installation and Commissioning:Installing the ABB UNITROL1020 3BHE030579R0003​is a systematic process involving mounting the cubicle,connecting high-power cabling to the generator field and excitation transformer,and wiring control signals and communications.Commissioning is a critical phase conducted with ABB’s proprietary software.It involves setting the generator parameters,performing the generator identification test for adaptive tuning,calibrating all I/O channels,and thoroughly testing all control modes,limiters,and protection functions—both in open-loop and closed-loop with the generator synchronized.A full functional test,including step response and rejection tests,validates the system’s dynamic performance.

Maintenance and Lifecycle Support:The system is designed for low maintenance.Key activities include periodic inspection of cooling fans/filters(for air-cooled TPPs),checking electrical connections for tightness,and verifying the calibration of key measurement transducers(VT/CT).The system’s comprehensive self-diagnostics and condition monitoring functions alert operators to developing issues like degrading thyristors or drifting sensors.We provide end-to-end support for the ABB UNITROL1020,from supplying genuine spare parts like controller modules and thyristor sets,to offering expert field service for troubleshooting and upgrades.Our support ensures your excitation system continues to meet evolving performance and grid code requirements throughout its extended service life.

Contact our power generation automation specialists to discuss how the ABB UNITROL1020 3BHE030579R0003 can optimize your generator’s performance,ensure grid compliance,and secure your critical power assets.

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