ABB has been selected to upgrade the turbine control system at the 1,300 MW Keppel Merlimau Cogen (KMC) combined cycle gas turbine facility on Jurong Island, Singapore, aiming to boost both reliability and efficiency. The project involves replacing the existing Egatrol 8 control system with the advanced Egatrol X system, based on ABB Ability™ System 800xA® and the modern AC800M portfolio.

This upgrade will transition the current system to the new solution without causing plant downtime, as ABB will implement the new technology in phases. The project plan includes upgrading DCS components while maintaining the existing system’s structure as much as possible. ABB’s approach involves replacing outdated components progressively, minimizing downtime and associated operational costs while ensuring a stable, reliable energy supply.

The transition process involves a proprietary software code conversion to adopt all control settings, reducing the need for manual adjustments. The updated user interface, built on System 800xA, requires only minor tweaks, thus avoiding extensive operator retraining. Additionally, ABB’s latest I/O evolution kit in the hardware design will cut commissioning time and mitigate the risk of re-wiring errors.

In line with Singapore’s goal to achieve net-zero emissions by 2050, the government is supporting business transformation through grants for energy efficiency and emissions reduction and investing in low-carbon technologies. Given that power generation contributes 40% of the country’s CO₂ emissions, Singapore aims to diversify its energy sources, focusing on solar energy, regional power grids, emerging low-carbon alternatives like hydrogen, and natural gas.

While natural gas remains a key component of the energy mix, the KMC project exemplifies ABB’s role in enhancing the efficiency and carbon performance of gas power generation. This initiative not only bolsters current energy security but also aids in integrating renewable energy into the grid, supporting the broader energy transition goals.

“As a leader in distributed control systems, ABB combines expertise with technology to deliver rapid and safe upgrades,” said Per Erik Holsten, President of ABB Energy Industries. “Our gas turbine control systems are pivotal in enabling utilities to provide efficient and sustainable electricity.”

“We are excited to continue our successful partnership with ABB through this latest turbine upgrade project. ABB’s extensive expertise ensures a seamless transition to the new system, crucial for maintaining our productivity and reliability in power supply,” said Miguel Benito, Assistant Managing Director, Technical and Operations, Power & Renewables, Infrastructure, Keppel.

This upgrade is part of KMC’s broader efforts to enhance system reliability, responsiveness, and efficiency, aiming to reduce fuel costs and environmental impact.

ABB’s Process Automation division focuses on automating, electrifying, and digitizing industrial operations to meet diverse needs, from energy and water supply to goods production and transportation. With around 20,000 employees, ABB Process Automation leverages leading technology and expertise to improve performance and safety, driving a sustainable and resource-efficient future.

ABB is a pioneer in electrification and automation, dedicated to advancing sustainability and efficiency. The company’s solutions integrate engineering knowledge and software to optimize manufacturing, movement, power, and operations. With over 140 years of experience and more than 105,000 employees, ABB is committed to fostering innovations that propel industrial transformation.

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