PAKISTAN PETROLEUM LIMITED

( KFGCS)

Diesel Genset
BY

ARSLAN AHMED AMIN

TRAINEE ENGINEER(E&I)

Abstract:
The Diesel Genset is used to supply power to the essential equipments in case of emergency when all the three gas gensets will not be available. It includes Diesel Generator skid, local control panel and remote control panel. It is capable of carrying full load current within 15 seconds and can withstand fault current of 300 times of the full load current for 10 seconds. It can bear 110% of full load continuously for two hours.

Introduction
The Kandhkot Field Gas Compression Station (KFGCS) has its own power generation unit which consists of three 2000KVA gas generators and one 700 KVA emergency diesel generator. Out of three gas gensets, only two operate at a time to bear the plant load. The remaining one remains on standby and comes in operation only in case of failure or emergency tripping of the other gas gensets. Diesel genset comes in operation only in the worst case when all three gas gensets have been tripped. Its job is to give power supply to essential plant equipments like PAGA system, fire water system etc which should always be operating to cope with the emergency situations. The Diesel Generator system consists of a Diesel Generator skid, local control panel and a remote control panel. The remote control panel is mounted away from the emergency diesel generator and located in the electrical switch room. Diesel Genet includes the following facilities: It is suitable for automatic start and is capable of carrying full load within 15 seconds. Connected to de-energized main bus (auto-starting and connection of the generator to a Dead bus). Automatic disconnection from the main bus and engine shutdown on the occurrence of a set malfunction. Automatic engine cranking facility. Six unsuccessful engine cranks in succession will result in Fail to Start Alarm Start and Stop emergency generator from Local Control Panel, Remote Control panel and interfaces with MCC EM-5400.

The engine/generator is capable of continuous operation between 30% and 100% of full load. In addition the unit is capable of 110% of full load for 2 hours.

Nameplate Data of Diesel Genset

Equipment Number: Output Power : Output Voltage: Frequency: No_ of phases: Rated Speed: System Fault Level: Insulation Class: Connection: Grounding Method: Exciter: EG-5400 700KVA/560KW 415 V 50 Hz 3 1500 rpm 65KA H Star neutral and frame directly earthed. Brushless

Starting System
The emergency Diesel Generator Set is supplied with single starting system. The starting system is dual redundant electric type and consists of 24V DC dual redundant batteries and dual redundant battery chargers with sufficient capacity to attempt six starts of 30 seconds each, in succession with 5 seconds interval.

Governor
Governor is suitable for droop, isochronous and base load mode of operation. Generator set speed is specified not to exceed 1 percent from no load to full load and safety state band is specified not to exceed 0.6 Hz. The governor is equipped for remote speed control from the remote control panel. Over-speed tripping is set at 115% and adjustable speed range is set to be within 85% to 105%.

Generator
The exciter is a rotating brushless type designed to provide an adequate range of excitation to allow the generator to operate with a satisfactory margin of stability under both steady and transient load conditions (e.g. large motor starting load). The generator is designed for solidly earthed neutral operation. It is capable of withstanding a maximum bolted single line-to-earth fault at its terminals for 10 seconds without damage, while operating with fixed full load excitation. In addition, the generator and excitation system is capable of withstanding a fault current of 300 percent of full load current without damage to the excitation level in the field winding, along with the associated short circuit heating and forces in the armateur windings. The generator and AVR incorporate integral overload protection. The voltage regulator, governor and other equipments are provided with radio interference suppression. Space heaters are installed in the generator to prevent condensation of moisture, when not in service and the rated voltage is 240V AC single phase.

Automatic Voltage Regulator (AVR) System

The voltage regulator provides automatic voltage built-up with 10% range of voltage adjustment. It is capable of sustaining 300% of generator full load current for 10 seconds during short circuit.

Motor Starting Capabilities

The generator is capable of starting a 50KW motor with DirectOn-Line (DOL) starter and a starting power factor of 0.4 while feeding a base load of 90KW and with the maximum voltage drop at the generator terminals being limited to 15%.

Black Start of Plant and Removal of Diesel Generator out of Service

During black start of the plant, normal power supply will not be available. The following procedure will be carried out to start the Diesel Genset: Start emergency Diesel Generator by energizing the start push button on the Diesel Generator control panel. The ACB-E can be closed after the following conditions are met: After receiving Diesel Generator run to normal speed and voltage from signal Diesel Generator remote control panel. After receiving MCC EM-5400 dead bus signal from Check Synchronization Relay in the Diesel Generator remote control panel. All normal supply ACBs i.e. ACB-NA, ACB-NB & ACB-NC are open. Bustie is open. Auto/Manual selector switch selected to Manual mode.

Parallel/Non-Paralleled selector switch selected to Non-Paralleled mode of operation. Once fuel is made available, bring one gas engine generating set on line, thereby making normal supply available the ACB-N can be closed after the following conditions are met: Bustie is open When either ACB-NA or ACB-NB or ACB-NC is closed and non-essential loads are energized, the bustie can be closed after the following conditions are met: Selector switch for Paralleled/Non-Paralleled operation changed to Parallel mode. Synchronization check relay output contact in Diesel Generator remote control panel indicates that supplies are synchronized Close ACB-N push button energized on Diesel Generator remote control panel. Reduce the load shared by Diesel Generator slowly, corresponding to the load shared by normal supply increases. Stop the emergency generator by pressing STOP Diesel Generator push button on MCC EM-5400.