HIPASE

General
Sales Manual

HIPASE
 Introduction

Identification SALESMANUAL\COMPLETE

Version.Revision 1.00COMPLETE

Date of issue 13.01.2016

This document is applicable to the following product(s):

HIPASE From V1.00

© 2016 by ANDRITZ HYDRO GmbH, All rights reserved.

Any kind of disclosure and reproduction whatsoever of this document or of parts thereof is
permitted only upon prior written consent by ANDRITZ HYDRO. Technical specifications are used
for purposes of product description only and are no guaranteed specifications in legal terms.
Subject to modifications - also in terms of technology.

2 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Introduction

Table of Contents

1. Introduction ........................................................................................................... 5
1.1. Integration on a highest level ...................................................................................................... 5

2. One platform – different devices ......................................................................... 7

2.1. Hardware ..................................................................................................................................... 7

3. Functions and features of HIPASE ...................................................................... 9

3.1. Hardware ..................................................................................................................................... 9
3.2. Device software ......................................................................................................................... 11

4. Licensing ............................................................................................................. 17

5. Service & Support Solution................................................................................ 19

5.1 Repair and Spare Parts Services .............................................................................................. 19
5.2 Service solutions ....................................................................................................................... 20

A. Reader´s Reactions ............................................................................................ 23

HIPASE Sales Manual General (e) MGB-011-1 (reviewed) 3 / 26

 Introduction

4 / 26 (reviewed) MGB-011-1 HIPASE Sales Manual General (e)

Introduction

1. Introduction

1.1. Integration on a highest level

ANDRITZ HYDRO has extensive and long term experience in the fields of excitation, electrical
protection, synchronization and automation of hydroelectric power plants. This experience formed the
basis for the development of the new HIPASE product platform. Highly performing and perfectly
adapted HIPASE integrates the specific requirements of the different fields in one single device.

The new and innovative HIPASE platform has especially been developed for the dedicated use in
hydroelectric power plants and covers the following applications:

 Excitation (HIPASE-E)
 Protection (HIPASE-P)

All devices are based on identical hardware modules and use the same engineering tool. Dedicated
electronic boards are used for specific requirements resulting in perfectly fitting devices for applications
like voltage regulators or generator protection functions.

This platform based idea results in various advantages. First of all spare part handling is a lot easier
when various systems of a hydroelectric power plant share the same electronic boards. Second of all as
the HIPASE Engineering Tool is the same for all applications it is a lot easier for engineers to handle
different systems as the all HIPASE applications are handled with the same PC program. Other
advantages like more efficient maintenance, easier training and the ability to have similar looks on the
integrated touch panels of the devices for different applications are more examples where the HIPASE
platform shines during the lifetime of the system.

ANDRITZ HYDRO is a global supplier of electromechanical equipment and services for hydroelectric
power plants. With over 170 years of experience and more than 30,000 turbines installed, totaling
approximately 400,000 MW output, ANDRITZ HYDRO is a leader in the world market for hydraulic
power generation, offering the complete product portfolio including turbines, generators and additional
equipment of all types and sizes.

HIPASE Sales Manual General (e) MGB-011-1 5 / 26

 Introduction

6 / 26 MGB-011-1 HIPASE Sales Manual General (e)

One platform – different devices

2. One platform – different devices

2.1. Hardware

HIPASE devices consist of a half size 19” housing incorporating up to 32 digital inputs and outputs as
well as 12 current and 8 voltage transformer inputs. For all applications with extensive signal
requirements (e.g. 6-system differential protection) a full size 19” housing can be used.

HIPASE devices usually carry four boards combined according the needs of the application. The
processor board is the core component providing system tasks, the calculation of dedicated programs
and also acting as a standard communication interface (e.g. IEC 61850, IEC 60870-5-103, IEC 60870-
5-104 and Modbus) to other devices or SCADA systems in the plant. For processing analog and digital
information dedicated I/O boards are provided.

A key characteristic of the HIPASE platform is its architecture. HIPASE ensures both the protection of
humans and property (safety) and data integrity (security) by hardware and software measures.

2.1.1. Engineering

As a result of predefined functions included in HIPASE all devices can easily be fitted to the dedicated
demands and plant specific requirements. The functional scope of the new HIPASE platform consists of
state-of-the-art and innovative technology like a fully graphical color touch panel, multiple open
communication features, certified safety and security features as well as a simple plant specific
configuration of the devices.

2.1.2. Security

Due to the complex interconnection between the overall infrastructure of power generation and
distribution, the issue of “cyber security” has become increasingly important. This importance
particularly becomes clear in the related policies of key power utilities (e.g. the White Paper of German
BDEW and the North American NERC CIP Standard).

Comprehensive and consistent security architecture protects HIPASE devices against cyber-attacks
from outside as well as from the internal network. The core elements of this architecture are an internal
firewall as well as encrypted transmission between HIPASE Engineering Tool and the HIPASE devices.
The HIPASE security features are provided by the hardware. Every HIPASE device is equipped with a
TPM chip (trusted platform module) which clearly identifies each device and provides unique keys for
authentication.

2.1.3. Consistent engineering

The HIPASE Engineering Tool is the perfect tool for an easy and efficient engineering of the HIPASE
platform. It is used for all applications such as excitation, protection and synchronization.

HIPASE Sales Manual General (e) MGB-011-1 7 / 26

 One platform – different devices

The HIPASE Engineering Tool is characterized by a future-oriented user interface and offers a new
quality of user friendliness with a workflow-oriented menu structure. The HIPASE Engineering Tool fits
perfectly to user requirements and demands. All major steps of a project like engineering,
commissioning, service and maintenance are greatly supported and easy to use.

In addition to standard functions user-specific application templates are available for protection and
excitation and allow fast and efficient engineering.

2.1.4. Device configuration

The device configuration allows the board placement in the housing as well as the adjustment of various
parameters (e.g.: threshold voltage). In addition the device configuration window is used for online
monitoring of input and output states.

2.1.5. IEC 61131-3 Function diagram

The graphical function block diagram editor is designed according IEC 61131-3. Additional application
specific function blocks are available in an extended function block library. An integrated online test
feature supports system test and commissioning. Other functions are the simulation of process data
through “forcing” or the individual blocking of process data.

2.1.6. Process displays

The fully graphical touch panel allows online visualization of process signals as well as the display of
internal data. Additionally it is possible to enter process parameters directly via the touch panel without
the need of an external device.

2.1.7. Data backup and restore

HIPASE Engineering Tool is capable of loading and reading back all parameters of a HIPASE device.
The uploaded parameters may be processed and re-loaded to the device at any time.

2.1.8. Multilanguage and Online help

HIPASE Engineering Tool is designed multilingual. Supporting additional languages is built right into the
program as well as it is built into the touch panel. A context sensitive multilingual help function supports
all engineering and maintenance activities.

8 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Functions and features of HIPASE

3. Functions and features of HIPASE

3.1. Hardware

HIPASE consists of a series of hardware modules which are developed for the dedicated use in
hydroelectric power plants. They are specially designed to fulfill the requirements and support a safe
and proper operation of the applications they are used for.

HIPASE devices come in two sizes. There is a medium housing (Half 19”) and a large housing (Full
19”). Both housings can be mounted in a (swing) frame and can also be mounted on the rear side of a
cubicle with a detached touch panel.

The family of HIPASE hardware boards consists of:

TR-310 Transformer Board 12CT, 8VT CP-300 Processor Board PS-300 Power Supply Board 110/220VDC DI, DO

AB-310 Application Board Excitation AB-310 Application Board Protection

HIPASE Sales Manual General (e) MGB-011-1 9 / 26

 Functions and features of HIPASE

3.1.1. Processor Board CP-300

Features the central processors, the interface to the other boards in the device and connects to the
process network and other communication media. This board takes care of the execution of the
software functions (like protection functions, regulators and others) and serves as the main boards of a
HIPASE device.

3.1.2. Transformer Board TR-310

This boards features 12 current transformer inputs (1/5 Ampere) and 8 voltage transformer inputs (100
VAC) which are sampled and transferred to the software functions every 1ms.

3.1.3. Power Supply Board PS-300 / PS-500

This board features the power supply for the HIPASE device. It can either be 24-60VDC (PS-300) or
110-220VDC (PS-500). Additional there are 4 fail safe digital output channels available on this board.
The Power Supply Boards can be equipped with additional digital input / outputs modules to suit the
intended application. Available modules are: 16DI (DI-010), 16DO (DO-010), 8DI+8DO (DX-010).

3.1.4. Application Board Excitation AB-310

This board features dedicated channels and functions for the excitation application like the regulation of
the trigger angles and the connection to the thyristor bridge. It can be equipped with an additional
module (AM-010) providing 6 analog input channels (4-20mA), 4 analog output channels (4-20mA) and
4 input channels for temperature measurement (PT100 sensors).

3.1.5. Application Board Protection AB-320

This board features dedicated channels and functions for specific protection functions like the earth fault
protection. It can be equipped with an additional module (AM-010) providing 6 analog input channels (4-
20mA), 4 analog output channels (4-20mA) and 4 input channels for temperature measurement (PT100
sensors).

3.1.6. Touch panel TP-900

The integrated touch panel of HIPASE devices provides state-of-the-art technology for displaying and
manipulating process data. It is freely configurable in terms of optical representation and in terms of the
kind and amount of data points which should be displayed. The HIPASE touch panel offers a leap
forward to all existing protection devices and excitation controllers with an intuitive user interface and
easy to use handling.

HIPASE complies with a number of different national and international standards. These are amongst
IEC 60255-26 Measuring relays and protection equipment
IEC 61131-2 Programmable controllers
IEC 61850-3 Ed 2.0 Communication networks and systems for power utility automation

10 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Functions and features of HIPASE

3.2. Device software

HIPASE devices feature a powerful platform built on state-of-the-art microprocessor technology for
calculating tasks and executing functions necessary for protection and excitation of hydroelectric power
plants.

The processor board acts as the center point for all calculations in a HIPASE device. It features dual
CPU design.
One CPU is designed to do all tasks necessary to guarantee a proper operation of all functions the
HIPASE device was loaded with. This includes all protections functions and functions for the regulators
of excitation applications as well as system tasks like the operating system and Watchdog functionality.
The execution of the user program can be separated into three tasks. This ensures the possibility to
achieve different cycle times for different parts of the application. This especially helps when several
parts (for instance control algorithms) of a program need to be calculated faster than other parts. With
this an overall better performance of the system can be achieved.

CP-300 Processor Board

TR-310 Transformer Board PS-300 Power Supply Board AB-310 Application Board

Besides this there is a second CPU on the processor board dedicated for communication interfaces.
The advantage of this design is that the external and internal Ethernet networks are separated. This
means that no external influence can harm the internal communication of HIPASE devices.
Even if the external communication breaks down, the local functionality of the device is ensured. This
measure underlines the security aspects which were put into the design of HIPASE.

These two CPUs on the processor board together with all other boards and the integrated touch panel
of every HIPASE device do communicate via an internal Ethernet Bus. This ensures a safe, stable and
fast transport of all data throughout the system.

HIPASE Sales Manual General (e) MGB-011-1 11 / 26

 Functions and features of HIPASE

3.2.1. Communication protocolls

HIPASE devices support the following international communication protocol standards:

IEC 61850 Ed 2.0

IEC 60870-5-104 Ed 2.0
IEC 60870-5-103
ModBus TCP

The engineering of these protocols is done in HIPASE Engineering Tool. A mapping feature provides
the possibility to connect map all internal information to a data point of the communication protocol and
vice versa freely. With the help of this a powerful interface can be engineered for connecting HIPASE
devices to control systems or SCADA systems within the hydroelectric power plant.

Recording analog and digital values and providing this information as a set for further analysis is
another feature of the HIPASE device software. The channels to be recorded can be defined freely and
therefor can be customized to the needs of specific applications.
Additionally to that disturbance records are also recorded and stored in the device and can be read out
with the help of HIPASE Engineering Tool and then saved in standard COMTRADE format.

Loading new user programs, parameters or even a new firmware is handled by the device software in
combination with HIPASE Engineering Tool. Every data download to a HIPASE device is verified and
will only be executed if the transmission went without error. The data transfer from the HIPASE
Engineering Tool to the HIPASE device is encrypted and therefor secure.
These measures ensured that no corrupt files can harm the functionality or availability of the system.

Additional functionality of the device software contains features like:

Time management

HIPASE devices get their time from external time servers like for instance an NTP Server. This time
information is used for time stamping of entries in chronological event lists or protocol telegrams.

Self-diagnostic and Watchdog

HIPASE devices feature powerful self-diagnostic capabilities. Hardware and software monitoring is
implemented on system level and monitors a wide variety of functions. Any detected error will put the
HIPASE device into a so-called “safe state” where additional damage on the system itself and of course
damage on the equipment it controls can be excluded.

Logging

An internal logging mechanism ensures a gap free log for all occurrences in the system. Loading
processes, restarts and parameter changes are only a small part of events which are recorded and
logged in the system. This log can be read out and analyzed with the help of HIPASE Engineering Tool.

12 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Functions and features of HIPASE

3.2.2. Engineering Tool

HIPASE Engineering Tool is state-of-the-art PC software for engineering all HIPASE device. It features
a modern user interface and a new quality of working with tools of such kind. The user is guided through
the whole engineering process, an efficient way of working is guaranteed. HIPASE Engineering Tool is
fully multilingual and offers a wide variety of customization options.

It follows the platform idea of HIPASE. Similar tasks are handled in a similar way, like the placement of
the hardware boards or setting an IP address. Special tasks like for instance the definition of the trip
matrix for protection devices can be done with dedicated designed user interfaces to provide the best
way of working for each and every task.

The main functions of HIPASE Engineering Tool are:

Defining the hardware configuration of HIPASE devices

An easy an intuitive way of placing boards to match the configuration of the HIPASE device to be
engineered. All available boards are presented in a library view and can be placed by the user.
Additionally a live update of all input and output channels is provided in this view.

Setting the parameter for input and output channels

Parameters like thresholds, input filters and others can easily be adjusted here to fit the requirements of
the different applications possible.

Programming and parameter setting of device function

HIPASE Sales Manual General (e) MGB-011-1 13 / 26

 Functions and features of HIPASE

With an integrated IEC 61131-3 compliant Function Block Editor a quick and standardized way of
working is assured. Predefined functions like protection functions or voltage regulators can be mixed
with user defined functions to fully customize the needs for every application possible. Parameters for
these functions can be directly set in the program or can be set via the integrated touch panel. In
addition also the configuration of communication interfaces takes place within HIPASE Engineering
Tool.

Drawing process display for the integrated touch panel of HIPASE devices

HIPASE Engineering Tool offers an easy to use full graphical editor for drawing the process displays for
the integrated touch panel of HIPASE devices. The configuration is done via predefined templates
which can be adopted freely to fit the needs of specific configurations. The touch panel offers integrated
parameter setting capability which means that all parameters of all functions can directly be entered on
the device without the need on an engineering tool. HIPASE Engineering Tool also features a simulation
mode for the integrated touch panel. This means that you can run the complete functionality of the touch
panel right on the PC you are working on without having a HIPASE device attached.

Commissioning, service and maintenance of HIPASE devices

During the commissioning HIPASE Engineering Tool supports the user with a lot of tailor made
functions for this task. For instance a fully featured online test for the Function Block Diagram with
forcing and blocking of all parameters and internal values helps a lot during this phase of a project. A
table view with live updates of a user defined set of parameters, input and output channels or even
internal variables helps to have a detailed look into the functions of a HIPASE device. The definition and
the read back of curves and disturbance records can also be done with dedicated designed user
interfaces within the program. Additionally a built in documentation feature ensures an easy way of
documenting all parts of a project.

HIPASE Engineering Tool is connected to the HIPASE device via encrypted data transfer over TCP/IP
on the process network. It is also possible to read back all parameters from a device into HIPASE
Engineering Tool.

14 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Functions and features of HIPASE

For additional user assistance a context sensitive help is built right into HIPASE Engineering Tool. With
the press of a button a help window displays help exactly for the part of the tool the user is currently
working with. Additionally the help also contains technical data for hardware boards and features easy
to use guides for the most common tasks done during all phases of a project.

HIPASE Sales Manual General (e) MGB-011-1 15 / 26

 Functions and features of HIPASE

16 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Licensing

4. Licensing

In order to ensure a safe and controlled way of operating HIPASE devices they are equipped with a
state-of-the-art licensing system. In general this means that for all software functions the device is
asked to execute a valid license has to be provided. As a result of this the operator can be sure that all
functions were commissioned properly and that he has legally purchased the desired functions.
ANDRITZ HYDRO on the other hand can be sure that only released functions are executed at a specific
plant.

Besides the hardware configuration also the desired software functions have to be specified during the
order process of a HIPASE device. The list of software functions available contains for example
protection functions, standard and advanced functions for the voltage regulator of excitation applications
or protocols for communication to other control devices or SCADA systems in the hydroelectric power
plant. After selecting the proper housing of the HIPASE device and the amount and types of the I/O
boards based on the input and output channels needed for the desired application you also have to
choose the necessary software functions. All this combined results in a HIPASE device perfectly fitting
for the application you need.

Every HIPASE shipment contains license information as well as the device itself. The software licenses
are tied to the device they were ordered for and can therefore not be transferred from one device to
another. This helps to have a consistent database of where specific software functions are implemented
and ensures that functions are used as intended.

The license information can be transferred into the device via HIPASE Engineering Tool.

If one or more software functions are running without valid license information in the device it will
indicate this matter on the integrated touch panel and also in internal log files. The user will also get
information about this as a warning presented in HIPASE Engineering Tool. During this state the “Error
Output” of the device will constantly remain “HIGH”, indicating that a proper and safe operation is not
possible without licensed software functions.

In order to ensure the best support possible it is of course possible to extend an already issued license
with one or more functions throughout the lifetime of a HIPASE device.

HIPASE Sales Manual General (e) MGB-011-1 17 / 26

 Licensing

18 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Service & Support Solution

5. Service & Support Solution

5.1 Repair and Spare Parts Services

ANDRITZ HYDRO repair service comprises all measures of examination and possibly restoring agreed
functionalities of a product. As part of repairs, improvements of the functionality are also possible. The
repair of electronic boards and other components provide an economical alternative to purchasing spare
parts.

A single point of repair gives you complete assurance that the repairs are done efficiently and safely

Overview

Following repair services are provided by Andritz:

 Standard repair

In a repair the functionality of the delivery state is restored. This includes, if required, also the
replacement of wear parts and possibly firmware upgrades.

Prerequisite for a repair is that the product is in a repairable state.

Cycle time for repairs is typically less than xx weeks ex works.

 Replacement

In a replacement repair the defect board will be exchanged. This includes, if required, also the
replacement of wear parts and possibly firmware upgrades.

Cycle time for repairs is typically less than xx weeks ex works.

 Spare part management

Privileged provision of boards for the purpose of quick exchange of faulty boards and delivery of
these boards to the customer within the specified period. We can jointly work out individual
solutions.

If you have any questions regarding repairs, please contact your Andritz contact person. He or she will
also tell you the address where you can send in the defective product.

Please have your data for identifying the affected product ready for your request, for example:

 Serial number of the device and/or single board

 Configuration code of the device

 Other name plate information

HIPASE Sales Manual General (e) MGB-011-1 19 / 26

 Service & Support Solution

 Fault report (included in every delivery and online available)

A full one-year warranty is included with every repair service for ANDRITZ HYDRO products and
systems.

5.2 Service solutions

5.2.1 Periodic inspection and maintenance

The service provides a periodic inspection and maintenance on-site at the customer plant by qualified
ANDRITZ HYDRO engineers.

The following services are included:

 Free of charge inspection and maintenance on-site at the customer plant within the specified
period as contracted.

 Inspection and maintenance in a defined period

Advantage for the customer:

 Early detection of faults and therefore higher availability of the system

 Increase of lifetime of equipment

5.2.2 Privileged standby with guaranteed response time

Privileged standby by qualified ANDRITZ HYDRO engineers for the purpose of troubleshooting and
customer support.

The privileged standby includes the following services:

 HOTLINE : consultation and support via telephone during the agreed support hours

 REMOTE DIAGNOSIS: remote access via telephone lines or internet to localize and eliminate
errors over long distances.

 SUPPORT TIME: During this period the qualified ANDRITZ HYDRO engineers are reachable.
e.g., the qualified ANDRITZ HYDRO engineers are reachable from
Monday – Sunday 8 AM – 5 PM

 RESPONSE TIME: The response time will be counted from the time, when the customer
requests an intervention with the agreed service point.
e.g. recall during x hour after fault report
e.g. remote diagnosis within x hours after fault report

Optional:
guaranteed on-site service within e.g. xx hours on workdays

Telephone support up to 2 hours per month are included (24 hours per year).

20 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Service & Support Solution

Advantage for the customer:

 Quick contact to qualified ANDRITZ HYDRO engineer during the agreed support time

 Technical support for the customer

 Short down time and higher availability of the system

 Optimal support in a staffing shortage situation

HIPASE Sales Manual General (e) MGB-011-1 21 / 26

 Service & Support Solution

22 / 26 MGB-011-1 HIPASE Sales Manual General (e)

Service & Support Solution

A. Reader´s Reactions

We designed and compiled this manual with great care and a high degree of responsibility. It is our goal
to design it in a way that it will be of greatest possible use at your work.

In order to reach this goal, we also rely on your cooperation - especially where maintenance and care of
the manual are concerned.

To make this cooperation easier for you, we added a form to this section. Please make use of it.

We will consider your comments in the next update of the manual.

Thank you very much for your cooperation!

HIPASE Sales Manual General (e) MGB-011-1 23 / 26

 Service & Support Solution

24 / 26 MGB-011-1 HIPASE Sales Manual General (e)

 Service & Support Solution

Form for Readers' Reactions

Your comments and suggestions will help us to further improve both quality and usefulness of
this manual. Thank you very much for your efforts!

Please fill in this questionaire and return it to us; we will send you the next update of this
manual free of charge as soon as it is available.

What is your impression of this manual? Do you think it is complete, correct and accurate, well-
structured, written in a comprehensible language, etc.?

......................................................................................................................................................................

......................................................................................................................................................................

Which parts, characteristics, aspects are particularly useful?

......................................................................................................................................................................

......................................................................................................................................................................

Does this manual meet the requirements that may reasonably be demanded? Does it come up to your
expectations?

......................................................................................................................................................................

......................................................................................................................................................................

Did you find any mistakes in this manual? If so, please use form on the backside.

................................................................. fold here for windowed envelope ......................................................

Please send a copy of this sheet (front and back) to the below address.

ANDRITZ HYDRO GmbH

Automation Product Management

Eibesbrunnergasse 20
A-1120 Vienna, Austria

HIPASE Sales Manual General (e) MGB-011-1 25 / 26

 Service & Support Solution

Correction Sheet
Sender: ..............................................................................................

..............................................................................................

..............................................................................................

Date: ..............................................................................................

Name of the document: ..............................................................................................

Version of the document: ..............................................................................................

Please correct the following items in the above documentation:

page wrong text should read...

For in-house use only: Korrigiert von:

Datum:

26 / 26 MGB-011-1 HIPASE Sales Manual General (e)