DTE Deutz Novi, Mi.

JOB # 7113P
DESCRIPTION OF OPERATION

Table of Contents
1. GENERAL...................................................................................................................................................2 1.1. EQUIPMENT DESCRIPTION......................................................................................................................2 2. ENGINE GENERATOR PRE-START CONDITIONS AND REQUIREMENTS..............................2 2.1. ENGINE SYSTEM................................................................................................................................2 2.2. SOFT LOAD CONTROL SYSTEM.....................................................................................................2 3. SEQUENCE OF OPERATION.................................................................................................................3 3.1. SINGLE GENERATOR START UP WITH UTILITY PRESENT (GRID PARALLEL OPERATION).....................3 3.2. MULTIPLE GENERATOR START UP WITH UTILITY PRESENT (GRID PARALLEL OPERATION)................3 3.3. SINGLE GENERATOR START UP WITH UTILITY PRESENT (ISLAND OPERATION)...................................4 3.4. MULTIPLE GENERATOR START UP WITH UTILITY PRESENT (ISLAND OPERATION)..............................4 3.5. SINGLE GENERATOR START UP WITHOUT UTILITY PRESENT (BLACK START CAPABILITY)................5 3.6. MULTIPLE GENERATOR START UP WITHOUT UTILITY PRESENT (BLACK START CAPABILITY)...........5 3.7. SINGLE GENERATOR RUNNING, LOSS OF UTILITY.................................................................................6 3.8. MULTIPLE GENERATORS RUNNING, LOSS OF UTILITY..........................................................................6 3.9. GENERATOR RUNNING, RETURN OF UTILITY........................................................................................7 3.10. GENERATOR(S) RUNNING, UTILITY PRESENT, GENERATOR SHUTTING DOWN...................................7 3.11. GENERATOR(S) RUNNING, UTILITY NOT PRESENT, GENERATOR(S) SHUTTING DOWN.......................7 3.12. ALARM SYSTEM OPERATION...............................................................................................................7 4. OPERATING INSTRUCTIONS...............................................................................................................8 4.1. BREAKER OPERATION (52G)..........................................................................................................8 4.1.1 BREAKER AUTO CLOSE OPERATION.....................................................................................8 4.1.2 MANUAL CLOSE OPERATION 52G...........................................................................................8 4.1.3 BREAKER TRIP OPERATION.....................................................................................................8 4.2. ENGINE CONTROL SWITCH.....................................................................................................................9 4.2.1 LOCKOUT/RESET ........................................................................................................................9 4.2.2 OFF/COOL DOWN.........................................................................................................................9 4.2.3 AUTOMATIC ................................................................................................................................9 4.2.4 TEST OFFLINE............................................................................................................................10 4.2.5 TEST ONLINE .............................................................................................................................10 4.3. OPERATOR INTERFACE TERMINAL (OIT)................................................................................10 4.4. ALARM SILENCE (PB1) AND FAIL TO SYNC RESET (PB2) PUSHBUTTONS........................11 APPENDIX A...............................................................................................................................................12 FACTORY DEFAULT SETTINGS...................................................................................................................12

1.

General
1.1. Equipment Description

The equipment covered by this order is a parallel to Utility (Cat 956) with Soft Loading capability. The Unit consists of a single section of indoor Switchgear. This is an integrated lineup that contains 1 breaker (a generator breaker.) The outputs of this breaker may be tied to a remote Utility mains breaker and/or additional generator paralleling breakers. Protective relaying and metering are provided as required. Controls are based on the Woodward LSM & SPMD and ASCO Power Manager XP with a GE 90/30 PLC provided for overall integration of functions. An Operator Interface Terminal (OIT) is provided for adjusting system parameters and controls. It is the intent of this document to provide information about the control system furnished by ASCO along with specific operating instructions and a sequence of operation. This document should be used along with manuals furnished by other equipment manufacturers for the complete operation and maintenance of this equipment and system.

2.

ENGINE GENERATOR PRE-START CONDITIONS AND REQUIREMENTS

2.1. ENGINE SYSTEM

The engine, generator, governor, regulator, and engine controls and accessories must be ready for operation and all systems set up for remote, automatic operation. Refer to the engine manufacturer manuals for proper set up and operation. 2.2. SOFT LOAD CONTROL SYSTEM

24 VDC control power must be available and turned on at the generator control panel. Acceptable voltage range is 20-30 VDC. If voltage exceeds these limits for an extended period of time, unit and or system failure will occur. There is a 24 V DC/DC converter installed in the gear to provide stable voltage during engine cranking.

Verify all alarm and status lights at the equipment are good by operation of the lamp test pushbutton. Verify the PLC is in the run mode via the run light on its power supply. All engine generator alarms and shutdown controls must be normal and reset and all alarm lights off. If any engine shutdown or alarm (red or amber light) is on, the engine may not start. The Engine Control Switch should be in AUTO for normal operation. Unit synchronizing mode, selected from the OIT, should be in RUN. A Controls Not in Automatic light will be lit if one of these switches is not in the correct mode.

3.

SEQUENCE OF OPERATION
3.1. Single Generator Start Up with Utility Present (Grid Parallel Operation)

With the Utility present and the Utility Mains breaker closed, upon receipt of a remote engine start signal, the generator mounted controller will be given a demand signal (DI1). Simultaneously, the Island Operation input (DI2) will be closed and the Black Start input (DI3) will be open, signifying the Start with Utility Present Grid Parallel condition. [Note: (DI#) and (AI#) refer to digital inputs or analog inputs to the generator mounted controller.] Once the generator has reached rated speed and voltage, as detected by the ASCO Power Manager XP, a Sync enable signal will be issued to the Woodward SPMD synchronizer. The SPMD will issue speed raise or lower signals to the generator mounted controller (DI5 & DI6) synchronizing the generator to the Utility. The SPMD will also match the voltage via the automatic voltage regulator (AVR) remote trim motor operated potentiometer (MOP), and then issue a close signal to the Generator circuit breaker (52G). When 52G is closed, the Power Switch input (DI4) to the generator will be turned on. The PLC in the ASCO soft load controller will then issue a Demand Power analog signal to the generator (AI1) and the generator will ramp the load to that level. Note: the Demand Power level is a base load set point set via the OIT (see Appendix A.) 3.2. Multiple Generator Start Up with Utility Present (Grid Parallel Operation)

With the Utility present and the Utility Mains breaker closed, upon receipt of a remote engine start signal, all generators will be given a demand signal (DI1). Simultaneously, the Island Operation input (DI2) will be closed and the Black

Start input (DI3) will be open, signifying the Start with Utility Present Grid Parallel condition. As each generator reaches rated speed and voltage, as detected by the ASCO Power Manager XP, a Sync enable signal will be issued to the Woodward SPMD synchronizer. The SPMD will issue speed raise or lower signals to the generator (DI5 & DI6), synchronizing the generator to the bus. The SPMD will also match the voltage via the AVR remote trim MOP, and then issue a close signal to the Generator circuit breaker (52G). When 52G is closed, the Power Switch input (DI4) to the generator will be turned on. Demand power settings are on a %Prated basis per unit and adjusted via the local OIT of each generator. Each generator will adjust itself to contribute its share of the Demand Power. The analog signals will be issued to the generators (AI1) and the generators will ramp to the required level. Note: the Demand Power levels are independent of each other, and the operator must make sure that the total base loading level does not exceed the system load of the bus; if levels are not adjusted properly, they system may try to export power to the utility.

3.3.

Single Generator Start Up with Utility Present (Island Operation)

With the Utility present but the Utility Mains breaker open, upon receipt of a remote engine start signal, the generator will be given a demand signal (DI1). Simultaneously, the Island Operation input (DI2) and the Black Start input (DI3) will be open, signifying the Start with Utility Present Island operation condition. Once the generator has reached rated speed and voltage, as detected by the ASCO Power Manager XP, a Sync enable and Dead Bus signal will be issued to the Woodward SPMD synchronizer. The SPMD will issue a close signal to the Generator circuit breaker (52G). When 52G is closed, the Power Switch input (DI4) to the generator will be turned on and the generator will take on the system load. If the system overloads a generator(s), a load shed relay will signal the condition. If the load is not reduced in time, a Bus Under-frequency condition will result and the breaker(s) will be tripped open, the generator(s) shutdown and locked out, and the condition annunciated. 3.4. Multiple Generator Start Up with Utility Present (Island Operation)

With the Utility present but the Utility Mains breaker open, upon receipt of a remote engine start signal, all generators will be given a demand signal (DI1). Simultaneously, the Island Operation input (DI2) and the Black Start input

(DI3) will be open, signifying the Start with Utility Present Island operation condition. Each generator shall be assigned a unique priority via its local OIT. A token will be passed from generator to generator based on priority. The first generator set to reach rated speed and voltage, as detected by the ASCO Power Manager XP, shall be connected to the bus. The priority interlock permits the connection of only one generator in the event of a simultaneous generator relay operation. Once the first generator is connected to the bus, the other generators will be synchronized to the bus and added via their SPMD. As each generator is added, the Power Switch input (DI4) to that generator will be turned on and the generator will take on the system load. Load share lines between the generators shall balance the load proportionally among the generators. System load shall be controlled by the plant so that it does not exceed the capacity of the system. If the system overloads a generator(s), a load shed relay will signal the condition. If the load is not reduced in time, a Bus Under-frequency condition will result and the breaker(s) will be tripped open, the generator(s) shutdown and locked out, and the condition annunciated.

3.5.

Single Generator Start Up Without Utility Present (Black Start Capability)

Without the Utility present, the Utility Mains breaker will be opened. The system will be in Emergency Mode and the generator will automatically be given a demand signal (DI1). Simultaneously, the Island Operation input (DI2) will be open and the Black Start input (DI3) will be closed, signifying the Black Start condition. Once the generator has reached rated speed and voltage, as detected by the ASCO Power Manager XP, a Sync enable and Dead Bus signal will be issued to the Woodward SPMD synchronizer. The SPMD will issue a close signal to the Generator circuit breaker (52G). When 52G is closed, the Power Switch input (DI4) to the generator will be turned on and the generator will take on the system load. If the system overloads the generator, a Bus Under-frequency condition will result and the breaker will be tripped open, the generator shutdown and locked out, and the condition annunciated. 3.6. Multiple Generator Start Up Without Utility Present (Black Start Capability)

Without the Utility present, the Utility Mains breaker will be opened. The system will be in Emergency Mode and all generators will automatically be given a demand signal (DI1). Simultaneously, the Island Operation input (DI2) will

be open and the Black Start input (DI3) will be closed, signifying the Black Start condition. Each generator shall be assigned a unique priority via its local OIT. A token will be passed from generator to generator based on priority and the first generator set to reach rated speed and voltage, as detected by the ASCO Power Manager XP, shall be connected to the bus. The priority interlock permits the connection of only one generator in the event of a simultaneous generator relay operation. Once the first generator is connected to the bus, the other generators will be synchronized to the bus and added via their SPMD. As each generator is added, the Power Switch input (DI4) to that generator will be turned on and the generator will take on the system load. Load share lines between the generators shall balance the load proportionally among the generators. System load shall be controlled by the plant so that it does not exceed the capacity of the system. If the system overloads a generator(s), a load shed relay will signal the condition. If the load is not reduced in time, a Bus Under-frequency condition will result and the breaker(s) will be tripped open, the generator(s) shutdown and locked out, and the condition annunciated. 3.7. Single Generator Running, Loss of Utility

If there is a Loss of Utility, the Utility present signal to the switchgear will go false. Simultaneously, the Utility Mains breaker will be tripped open. Since the generator is already running and the paralleling breaker (52G) is already closed, the system will immediately switch from GPM (Grid Parallel Mode) to GIM (Grid Independent Mode). The generator will take on the system load (PL). If the system overloads a generator(s), a load shed relay will signal the condition. If the load is not reduced in time, a Bus Under-frequency condition will result and the breaker(s) will be tripped open, the generator(s) shutdown and locked out, and the condition annunciated. 3.8. Multiple Generators Running, Loss of Utility

If there is a Loss of Utility, the Utility present signal to the switchgear will go false. Simultaneously, the Utility Mains breaker will be tripped open. Since the generators are already running and the paralleling breaker (52G) is already closed, they will immediately take on the system load (PL). The load share lines and the master controller shall ensure that system load is shared proportionally by each generator. If the system overloads a generator(s), a load shed relay will signal the condition. If the load is not reduced in time, a Bus Under-frequency condition will result and the breaker(s) will be tripped open, the generator(s) shutdown and locked out, and the condition annunciated.

3.9.

Generator Running, Return of Utility

With the system operating in GIM, the UIC detects Utility source availability and the Utility Present signal goes true. Upon receipt of the Utility Present signal, the synchronizer in the UIC will issue speed raise and lower signals (via the generator control PLC) to synchronize the generator across the utility breaker and, after achieving synchronism close the utility breaker. The system will be back in GPM, and the generator will be brought back to the base load set point level (PG). Note: the UIC is the Utility Interconnect Controller and its functions include Source sensing and breaker control. 3.10. Generator(s) Running, Utility Present, Generator Shutting Down While operating in GPM, the Remote Start signal is removed. The generator(s) will be soft unloaded by ramping down to the unload trip level set point (factory set at 35%) and the breaker(s) 52G will trip open. The generator(s) will run through a cooldown cycle and shut down. 3.11. Generator(s) Running, Utility Not Present, Generator(s) Shutting Down If, while operating in GIM, the Remote Start signal is removed, breaker(s) 52G will open and the generator(s) will run through a cooldown cycle and shutdown. 3.12. Alarm System Operation The alarm system consists of a status panel, with a central audible alarm and a manual Alarm Silence Pushbutton (PB1). Status lights are green, red or amber and do not turn on the horn. They are used for breaker status. Pre-alarms are amber and all shutdowns are red. Each of these alarms turns on the audible alarm. The audible alarm must be manually turned off using the Alarm Silence Pushbutton (PB1). Actual engine shutdown is controlled at the engine. Breaker 52G will be tripped open for each shutdown. The audible alarm horn will turn on for subsequent alarms. The alarm system includes pulse modules, which latch each alarm as it is received and provides

momentary pulse to the horn which seals in through the horn relay. The horn will remain on until silenced.

4.

OPERATING INSTRUCTIONS
4.1. BREAKER OPERATION (52G)

The Generator breaker is a Merlin Gerin MASTERPACT Universal Power Circuit Breaker rated 1600 A frame with 1600 A trip rating plug. 4.1.1 BREAKER AUTO CLOSE OPERATION Once the generator has reached rated speed and voltage, the generator breaker will be automatically closed to a dead bus, or after the generator has been synchronized to an energized bus. Automatic closing of the Generator Breaker will be prevented if the Generator breaker has been tripped due to overcurrent, lockout, or if engine shutdown overrides normal sequence. 4.1.2 MANUAL CLOSE OPERATION 52G The Manual Close logic provides Dead Bus closing capability. This capability is enabled when there is no voltage on the main bus and the Utility Mains breaker is open. If the Utility is not present, the operator should confirm that the Utility breaker is open and that there is no voltage on the main bus. Then the operator may close breaker 52G using the Circuit Breaker Control Switch located on the door the of the generator control cubicle. If there is voltage present on the main bus, a sync check relay will prevent the operator from manually closing the breaker while the sources are out of phase. The operator can make speed corrections using the speed adjust switch on the generator control panel. When phase is matched (as detected by the Sync Check Relay), the breaker can be closed by using the Circuit Breaker Control Switch. 4.1.3 BREAKER TRIP OPERATION The breakers will automatically open for the following functions: Normal sequence will operate the breakers as described in the sequence portion of this document.
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Engine shutdown or bell alarm will cause the generator breaker to trip and lockout until manually reset. 4.2. Engine Control Switch Note: the remote ECS located at the generator must be in Auto for these functions to operate. 4.2.1 LOCKOUT/RESET When placed in this position, the Engine Generator set is locked out from start operation. If the Engine Generator set was shut down due to an Engine malfunction, the shutdown malfunction will be reset. If the Engine is running when the switch is moved to this position, it shall be immediately shut down without a cool down period. If the Generator circuit breaker was closed, it shall be immediately tripped open. A red flashing "Controls not in Automatic" status light will indicate the switch is in this position. A lock out relay is provided for interconnection with the generator in order to ensure the generator cannot be started locally. 4.2.2 OFF/COOL DOWN In this position, if the Engine Generator is running in Grid Parallel Mode, the generator will be soft unloaded before the circuit breaker trips open. In Grid Independent Mode, the breaker will trip open immediately. In either condition, the Engine Generator set shall run for a cool down period, as set at the generator. If the Generator controls are already receiving a remote start, an alarm will sound and the Generator is considered to be shut down. An Engine Generator set can not be started automatically when the switch is in this position. A red flashing "Controls not in Automatic" status light will indicate the switch is in this position. Note: the generator is not locked out from a remote manual start while the control switch is in this position 4.2.3 AUTOMATIC With the switch in this position, the Engine Generator set controls are ready for automatic operation upon receipt of a remote start signal. The Engine Generator will start, run, and the Generator circuit breaker will be closed to the Generator Paralleling Bus (per the sequence described in Section 3.) If the start signal is removed while in GPM, the Generator will be soft unloaded and the circuit breaker will be opened at the unload trip level (factory set at 35%). In GIM, the breaker will open immediately. In either Mode, the Engine Generator will run for the cool down period.

4.2.4 TEST OFFLINE With the switch placed in this position, the Engine Generator set shall immediately start and run. In this mode, the Generator circuit breaker will remain open and shall not be connected to the Generator Paralleling Bus unless a start signal is received. If a start signal is received, automatic operation will be initiated as described in "Automatic". If the start signal is removed while in GPM, the Generator will be soft unloaded and the circuit breaker will be tripped open. In GIM, the breaker will open immediately. In both modes, the Engine Generator will continue to run as long as TEST OFFLINE is selected. 4.2.5 TEST ONLINE When placed in this position, the Engine Generator set shall immediately start and run. If the bus is energized, the generator will synchronize and close to the bus. Once paralleled to the Utility (GPM), the generator will ramp to a minimum load level (factory set at 40% in the System PLC). If a start signal is subsequentially received, the Generator circuit breaker will remain closed and the generator will ramp up to the serially adjusted load set point received from the UIC. If the Remote start signal is removed, the Generator circuit breaker will remain closed and the Generator will ramp back down to the Minimum Load set point. The Engine will continue to run as long as TEST ONLINE is selected. Exiting TEST ONLINE mode will soft unload the generator before tripping the breaker, unless the generator is put into LOCKOUT/RESET. Note: this mode is typically unavailable if the bus is de-energized (GIM) because the Emergency Mode auto start signal would override any test mode. However, if the main bus is de-energized and no auto start has been received, the Generator shall start and run, but will not close on the dead bus. The breaker may be manually closed using the CBCS. In this condition, the Generator will take on the entire system load, provided it does not exceed the generators capacity. Caution: if multiple generators are in Test On Line each generator will be automatically loaded to 40% of its capacity; if there is not enough system load, power will be exported to the utility. 4.3. OPERATOR INTERFACE TERMINAL (OIT)

A Quickpanel Jr. Operator Interface Terminal is provided for setting base load parameters, generator priorities, time delay settings, and control switches for different control modes. The following is a brief description of each screen: Screen 1 - (Title) - this screen contains information that is relative to the job.

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Screen 2 - (Control Station) - this screen contains the Sync Mode Selector Switch. Screen 3 - (Timer Delays) This screen provides numeric data entry for the Return to Normal Time Delay. Screen 4 - (Generator Settings) This screen provides numeric data entry for the Number of gens in the system and the Generator priority. Also, an error message will appear if there is an invalid entry. The error message is cleared when a correct entry in made or when the page is exited. Screen 5 - (Load Settings) - This screen provides numeric data entry for the Base Load %kW set point. 4.4. ALARM SILENCE (PB1) AND FAIL TO SYNC RESET (PB2) PUSHBUTTONS

The horn silence pushbutton will turn off the horn but not clear any alarms on the status panel. In order to remove all alarms and shutdowns, the generator ECS must be taken into the Lockout/Reset position The Fail To Sync reset pushbutton will remove indication of that condition only.

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Appendix A
Factory Default Settings Label Base Load kW% # of Gens in System Gen. Pri. Return to Normal Description Base Load Set Point Percentage Number of Gens in the system Generator Priority Retransfer to Normal Time Delay Range (40%-100%) (1 5) (1 5) (0 1800) Factory Settings 80% 1 1 60

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