3 Day1 - Plant Operation Modes RAF - Handout

Wärtsilä Land and Sea Academy
II. Plant Operation Modes

Version 1.0
© Copyright 2007, Wärtsilä Land and Sea Academy Inc. Page 1 of 23

Introduction to Start, Stop and Operation
The genset consists of a Wärtsilä 18V46 engine acting as a prime mover driving an ABB AMG1600SS12 DSE
three-phase AC generator.
The following units and components are identified in the illustration:
1. Turbo charger
2. Engine
3. Generator
4. Base frame
5. Steel springs
6. Flexible coupling
The engine and generator are connected using a flexible coupling. The flexible coupling ensures that the
generator and the engine do not affect each other adversely due to smaller deviations in alignment,
temperature movements or any dynamic free forces.
For the same reasons are all external piping systems connected to the engine via flexible connections.
Transmission of vibration and structure born noise is minimised by having the Engine and generator solidly
mounted on base frames and base frames flexibly mounted on the foundation by steel spring elements.
PP Electrification / RLO2 ver 1.0 © Copyright 2007, Wärtsilä Land and Sea Academy Inc. Page 2 of 23
Engine Main Data
The Wärtsilä 18V46 diesel engine is a medium speed, intercooled and turbocharged, 4-stroke engine with
direct dual fuel. The engine has the following main characteristics:
Configuration V-form
Number of cylinders 18
Cylinder bore 460 mm
Stroke 580 mm
Speed 500 rpm
Number of valves per cylinder 2 inlet valve, 2 outlet valves
Direction of rotation Clockwise (facing flywheel)
Generator Main Data

The ABB AMG1600SS12 DSE generator is a synchronous, self-cooled, 3-phase, brushless, two bearing type
generator design with the following main characteristics:
Output 19091 kVA

Power factor 0.80
Voltage 11000 V
Frequency 50 Hz
Current 1002 A
Speed 500 rpm
Efficiency 97.80 at 0.80 p.f. 100 % load
Insulation class F
Protection IP23
Function
The basic function of the genset is to produce electricity by having the engine in operation and thus driving
the generator.
Operation at loads below 20 % of rated output should be limited to maximum 100 hours continuous operation.
Run the engine above 70 % of the rated load for at least one hour before continuing low load operation
This is to simplify the “function” in extreme, and the genset cannot perform these functions without the aid
of complex auxiliary systems, control and monitoring system and electrical distribution system.
Control and Monitoring System

The engine control and monitoring system consists of several PLC (Programmable Logic Controller) units.
Each genset has one PLC located in the genset section of the central control panel. One common PLC, which
takes care of common functions of all gensets, such as synchronising, is located in the common section of the
central control panel. There is also one PLC for each genset located in the genset local control panels. All
these units are connected to the WOIS workstation via the control network.
The PLC installed for the genset controls the operation of the genset and collects and transfer information to
the central processing unit. The common PLC unit installed and shared by all gensets collects and transfer all
common information and controls all common processes.
Electrical Distribution System
The main switchgear or MV-switchgear (Medium Voltage) is the 11 kV system used to provide customers with
electricity via the distribution transformers. The LV-switchgear (Low Voltage) is the 400 V system used low
voltage electricity for electrical consumers of the power station thus ensuring continuous and reliable
operation of the auxiliary equipment.
The electricity for own consumption is normally supplied by the genset via station auxiliary transformers
connected to the plants MV system. A “black-start” unit is provided to supply power in case the gensets are
down and it is not possible to receive electricity from the public utility system.
Auxiliary Systems
The function of the auxiliary systems is to provide the engine with fuel, lubricating oil, compressed air,
cooling air, and charge air at a required quantity and quality, as well as to dispose exhaust gases in a proper
manner.
Therefore the auxiliary systems are essential for the proper function of the engine. The auxiliary equipment
should be in a full operational condition when the engine is in operation or in stand-by.
Note that all systems are equally important and even though some by-pass functions may exist, these are
only measures provided for short-term use during maintenance, for example.
To start engine safely and economically, engine must have:

1) Lubrication
2) Fuel
3) Cooling
4) Power to Rotate (air)
Engine Control System
Engine Control System
The power plant can be controlled essentially from the following places;
at the central control panel CFA901 and,

at operator's station PC called WOIS.
The central control panel contains the operating switches and push buttons for the synchronization
equipment and the control/mimics for the plant MV and LV systems.
The enginewise functions can be monitored at the operator's PC. The enginewise CFE0_1 panel contains the
speed controller, the speed measuring system, the AVR (Automatic Voltage Regulator), the PLC for the
generating set, the hardwired engine shutdown and breaker trip circuits.
The enginewise protection relays are located on CFC0_1 panel. In addition to these there are several local
control panels which are attached to their respective units (for example the separator unit has its own local
control panel).
Introduction
The starting and stopping of the power plant is made manually or automatically with manual order, while
power regulation and synchronization can be made either in auto mode or manual mode.
All the manual control and adjustment measures needed for the diesel generator is carried out by M1-unit of
generating set. The CFC0_1 sections contain selectors for the generating set operation modes as well as the
control switches for manual control.
In Auto mode the PLC system software performs the start sequence, the load control and the stopping
sequence. The PLC system monitors the status of the engine continuously and therefore it is not possible to
run the generating set without the PLC.
The names of the local control panels are for example as follows:
BJA0_1 Pipe module control panel

BJL901 LFO Feeder unit panel
BEY901 DC-system
BLA90_ Starting Air units
BLB901 Working Air unit panel
BLM901 Black Start unit panel
Start Up Sequence
It is assumed that all units are shut down and that power is available from the main grid. It is also assumed
that all units are in operational condition.
Some of the actions to take depend on the length of time the plant has been shut down and may not be
required if the plant has been shut down for a brief period only. In such cases the decision of what to
exclude must be left to the discretion of the operating personnel.
Occasionally during stoppage, covers are removed for measurements and checks. Before start it must be
made sure that all covers and protective shields are mounted properly.
Start of the Genset
1) Start the genset from the central control panel or from the WOIS workstation.
2) Check that the pressure and temperature readings are normal.
3) Check for alarms.
Synchronizing the Genset

1) Synchronize the genset to the busbar and grid.
When connecting to a live busbar, the connection must be synchronized.
When connecting to a dead busbar, no synchronizing is needed.
Normal Operation Supervision

There are no automatic supervision or control arrangement that could replace an experienced engineer’s
observations!
Look, listen, feel the engine!

Take care of low load operation restrictions
Remember cleanliness!
Check temperatures and pressures regularly
Check for leaks, loose components
Attend to alarms promptly
Check vents/drains
Plant Operation
Shutdown Circuit
Shutdown
The shutdown circuit will open the generator breaker and disconnect the excitation. The engine stops
immediately by the engine PLC. The hardwired circuit is self holding and will remain on until it is reset by
push button. The genset cannot be started on in this case. The indication light indicates that the shutdown
circuit is activated.
Tripping and Blocking Circuits
Tripping
The breaker trip circuit opens the genset breaker and disconnects the excitation of the generator. After the
breaker has been opened and excitation disconnected the genset runs unloaded for a preset time before it
stops.
The breaker trip circuit is self holding over an auxiliary contact and will remain on until it is reset by the
tripping reset push button. Before restart the cause for tripping must be investigated and remedied.
Blocking
The blocking circuit opens the genset breaker, disconnects the excitation and stops the engine immediately
without any recooling time.
The blocking circuit is self holding over an auxiliary contact and will remain on until the blocking reset
button is pressed. The genset cannot be started if the shut-down circuit is activated. Before restart the
cause for blocking must be investigated and remedied.
Control Modes
Control Panel
• MEASURING
• SUPERVISION
• CONTROL
• PROTECTION
Control Plate
ENGINE DG-SET CONTROL ENGINE GENERATOR CONTROL

START STOP AUTO MANUAL SPEED kW VOLTAGE P.
droop droop F
S S S S S
BREAKER FUEL EXCITATION
7
CLOSE 8
OPEN 1 DEC.2 INC
DEC. 3 INC
S S1 S S
ENGINE BREAKER
SYNCHRONISING
9
SHUTDOWN 0
TRIP
LAMP TERST
4 50 SELECT/START
S1 S1 S1 S
1 2 3 6
S1 DG-Set Control Auto/Man

S2 Engine Control Droop Or KW/ISO
S3 Generator Control Droop Or P.F
S4 Fuel Inc./Dec.
S5 Excitation Inc. / Dec
S6 Synchronising Start
S7/S8 Engine Start/Stop
S9/S10 Breaker Close/Open
S11/12 Shutdown/Trip Reset
S13 Lamp Test
Different Control Modes
Isochronous control
kW control
Engine control
Speed droop control
Voltage control
Generator control Pf/Var control
Voltage droop control
DG-SET CONTROL ENGINE GENERATOR CONTROL
AUTO MANUAL SPEED ISOCHR. VOLTAGE AUTO

droop droop
S1 S2 S3

droop droop
S1 S2 S3

droop droop
S1 S2 S3
Parallel Operation
Share load ?
Synchronous Generator - Control Methods
Control Methods For Diesel Power Plants
Island System
On ships and power plants which are isolated from other systems; mine sites and small islands, System
voltage is determined by generators and their voltage control system. Generator reactive load varies
depending on system loading.
Control method is voltage control with or without droop and with or without cross-current compensation.
Utility System
Base load stations, System voltage is determined by the utility, generators usually cannot affect the voltage
Control method is power factor control or reactive power control.
Voltage control mode
Voltage control without droop can be used for single generator when generator shall only maintain the
terminal voltage at pre-set value.
Voltage droop control is a universal, flexible control method, which can be used in single unit operation, in
parallel operation with other units in an island system or in parallel operation with the rigid utility - due to
voltage droop, the line voltage drops with increasing reactive power.
Power Factor / Reactive Power Control Mode
2) Power factor control keeps the angle constant regardless of the output P
3) Reactive power control keeps the reactive power constant regardless of the output P
4) Power factor control and reactive power control modes are possible only when a generator is connected
to a larger power system, where other synchronous machines (big majority of output) determine voltage
and can absorb reactive power.
Note!
Before synchronizing to the network, the generator must always operate in voltage control mode
What to control at Power Plant ?
P/k
W
S/kVA
Q/kVa
S² = P² + Q², r
where
S = Apparent Power, kVA
P = Active Power, kW
Q = Reactive Power, kVar
cos = P/S
During normal operation we have to take care both:
active power
reactive power control
Parallel with Grid
DG-Set Control At Base Load System

Auto
1) Engine control
kW enable
2) Generator control
P.F. enable
3) PLC takes care via primemover controller Woodward723 and ABB Unitrol1000 that kW and P.F. setpoints
are maintained.
Manual
1) Engine control either SPEED DROOP or kW mode:

active load reference is changed by S4-button, FUEL increase / decrease command
2) Generator control either VOLTAGE DROOP or P.F. mode:
reactive load reference is changed by S5-button, EXCITATION increase / decrease command
Speed Droop Control
True kW Control
Island Operation Mode
Isochronous Speed Control
Digital Speed Controllers
Advantages
1) Better performance
2) new control methods
3) Easy to adjust, when person is familiar with the controller
4) Possibility to create “standard” settings as adjustments are given as numbers
5) No drafting in setting values
Disadvantages
1) More expensive
2) Requires more understanding of speed control basics when adjusting, because there are more parameters
Generator Control Methods

Island System
On ships and power plants which are isolated from other systems; mine sites and small islands
System voltage is determined by generators and their voltage control system
Generator reactive load varies depending on system loading
Goal: stable system voltage
Parameter: voltage
Utility System
Base load stations

System voltage is determined by utility, generators usually cannot affect the voltage
Generator reactive load is proportional to engine load
Goal: stable power factors on generators
Parameter: power factor
Digital Voltage Controller

Advantages
1) Good performance
2) Limiters for generator protection
3) Easy to adjust, when person is familiar with the controller
4) Possibility to create “standard” settings as adjustments are given as numbers
5) Interchangeability through “standard” settings
6) No drifting in setting values
Disadvantages
1) “Different” technology, takes time for people to get used to it

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Wärtsilä Land and Sea Academy

II. Plant Operation Modes

© Copyright 2007, Wärtsilä Land and Sea Academy Inc. Page 1 of 23

Generator Main Data

Output 19091 kVA

Control and Monitoring System

Electrical Distribution System

To start engine safely and economically, engine must have:

at the central control panel CFA901 and,

BJA0_1 Pipe module control panel

Synchronizing the Genset

Normal Operation Supervision

Look, listen, feel the engine!

ENGINE DG-SET CONTROL ENGINE GENERATOR CONTROL

S1 DG-Set Control Auto/Man

Speed droop control

Generator control Pf/Var control

Voltage droop control

DG-SET CONTROL ENGINE GENERATOR CONTROL

AUTO MANUAL SPEED ISOCHR. VOLTAGE AUTO

AUTO MANUAL SPEED ISOCHR. VOLTAGE AUTO

DG-SET CONTROL ENGINE GENERATOR CONTROL

AUTO MANUAL SPEED ISOCHR. VOLTAGE AUTO

Synchronous Generator - Control Methods

Control Methods For Diesel Power Plants

Voltage control mode

DG-Set Control At Base Load System

1) Engine control either SPEED DROOP or kW mode:

Isochronous Speed Control

Generator Control Methods

Base load stations

Digital Voltage Controller

1) “Different” technology, takes time for people to get used to it

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