ABB modernizes gas turbine control system to increase reliability and efficiency at Singapore power plant

Summary

ABB has been selected to upgrade one of the turbine control systems at the 1,300 MW Keppel Merlimau Cogen (KMC) combined cycle power plant on Jurong Island in Singapore to improve efficiency and reliability.

The scope includes replacing the existing Egatrol 8 turbine control system with Egatrol X, which is based on ABB’s flagship Ability System 800xA distributed control system (DCS) and the modern AC800M portfolio.

By transferring the full functionality of the existing application to the upgraded solution, the customer can avoid downtime and install the control system in the shortest possible time. The project involves upgrading DCS components while preserving the overall structure as much as possible. Instead of having to rebuild the entire system at once, ABB offers a flexible, tailored approach where older components are replaced as needed. This prevents unnecessary downtime, avoids the costs associated with operational failures and ensures a stable, reliable power supply with high availability.

All control settings are adopted through an internal software code conversion process, eliminating time-consuming adjustments to system parameters. The System 800xA-based user interface requires only minor adjustments, eliminating the need for operator retraining. The hardware design with ABB’s latest I/O evolution kit significantly reduces commissioning time and eliminates the risk of rewiring errors.

As part of Singapore’s commitment to achieving net-zero emissions by 2050, the government is encouraging business transformation through energy efficiency and emissions reduction grants. It is also investing in low-carbon technologies to drive the energy transition. With electricity generation currently accounting for 40 percent of carbon dioxide emissions, the country plans to diversify its energy supply, focusing on four areas: solar energy, regional power grids, new low-carbon alternatives such as hydrogen and natural gas.

Natural gas continues to play an important role as the country expands its energy portfolio. The KMC project demonstrates how ABB enables its customers to improve energy and carbon efficiency in gas-fired power generation. This initiative not only secures current energy security but also supports the integration of renewables into the grid, driving the shared goals of the energy transition.

“As a global leader in the DCS market, ABB has the expertise and technology to deliver flexible, customized upgrade installations as quickly and safely as possible,” said Per Erik Holsten, President of ABB Energy Industries. “Turbines are the heart of a power plant and our gas turbine control systems help utilities deliver electricity to homes around the world as efficiently and sustainably as possible.”

“We are delighted to renew the long-standing partnership between Keppel and ABB with the latest turbine upgrade project. Thanks to ABB’s extensive expertise, we are confident that KMC will experience a smooth and seamless migration to the upgraded system, which is critical to our productivity and ability to reliably supply power to the grid,” said Miguel Benito, Deputy General Manager, Engineering and Operations, Energy & Renewables, Infrastructure at Keppel.

This is part of KMC’s ongoing initiatives to introduce automation solutions to improve system reliability and responsiveness to achieve greater efficiency, lower fuel costs and reduced environmental impact.

About ABB

ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions combine engineering and software to optimize how things are made, transported, powered and operated. Building on over 140 years of excellence, ABB’s more than 105,000 employees are committed to driving innovations that accelerate industrial transformation.

---

---