sync generator example

5/28/2018 sync generator example

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Standby Diesel Generator Set


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1. State the purpose/main function of standby generator installation.

2. State, explain and identify the standby generator set assembly.

3. State, explain and identify the main component of AC Generator.

4. Describe the operation of Brushless Generator type.

5. Describe the metering, protection and control system.

6. State and explain the controlled parameters of Standby generatorinstallation.

7. Read and interpret layout drawing/diagram of Standby generatorinstallation.

8. Perform pre-start up inspection on Standby generator installation.9. Perform Standby generator startup and shutdown according to

standard procedure.

Objectives



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System function and Assembly

Generator Principle and Components

Brushless AC Generator Construction

The Generator ExcitationGenerator Control Panel System

Starting System and Component

System Operation

Start-up/Shutdown

Start-up Procedure

Coverage



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to deliver power automatically to essential and vitalswitchboards in the event of power failure in order to poweredthe critical equipment such as UPS systems, Plant shutdownsystem, DCS, instrumentation,main motors, DC battery chargers

and emergency lighting.

Function

Lightning

Arrestor

/SYNCHRONIZING

Lightning

Arrestor

Lightning

Arrestor

VITALSWITCHBOARD

AMFBOARD

Lightning

Arrestor

NeutralSwitch

- DCS

- FireandGasDetectionSystem

- OverheadSystem

- StreetLighting

- OverheadSystem

- StreetLighting

Main SwitchBoard

Essential Switch

Board Vital Switch

Board

Generator/

Synchronizing

Switch Board

AMF Board

Sub Switch

Board

Power Flow



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Assembly

Prime Mover - Diesel Engine

AC Generator

Fuel Storage

Generator Switch Board

Generator Control Panel

Battery Bank and Starting System



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AC Generator (Basic)

converts mechanical energy to electrical energy.

Prime mover

provides mechanical

power in term of rotation.

converts mechanical

power into electrical power

Generator/Alternator

Function


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"Whenever a conductor or coil cuts a magnetic field or

vise-versa, an induced current will flow in a conductor or aninduced voltage will exist across the conductor"

Principle



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Construction / Main components

Armature Winding

Field Winding

AC Output

DC input from

Exciter

N

N

S

SRotation


Stator

Rotor

Frame of Yoke


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Requirements

2 Conductor or Coil

- a copper conductors known as Armature winding, carryinduced current when cutting process occurs.

1 Magnetic Fluxes

- produce by a copper conductors known as Field windingwhen receives a DC supply from exciter.

3 Cutting Process

- is a process where a conductor cuts the magnetic field or amagnetic field cuts the conductor which results and inducecurrent flow in the conductor.

AC Generator (Basic)AC Generator (Basic)


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1. Generated Voltage or Output Voltage ( E )

E = B l v sin q in volt (V)

Where , E = output voltage

B = Magnetic field strength

l = Length of conductor under magnetic flux

v = speed of generator

q = cutting angle

E Exciting Current and speed

AC Generator (Basic)AC Generator (Basic)

Performance


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2. Frequency ( f )

pN

120

fgenerator speed

f = in Hertz ( Hz )

Where, p = number of poles

N = speed in rpm


Performance


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3. Generator Speed ( N )

120f

p

N = in Hertz ( Hz )

Where, p = number of poles

f = frequency


Performance


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P = V I cos q - Watt or Kilowatt ( kW ) or

P = V I - VA or Kilovoltamp ( kVA )

4. Output power ( P )

P = V I cosq - Watt or Kilowatt ( kW ) orP = V I - VA or Kilovoltamp ( kVA )

For a Single phase

For a Three phase

3

3

where V = line voltage

I = line current

cosq= power factor


Performance


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5. Generator Efficiency ( )

=

Output Wattage

Input Wattagex 100

Copper loss = P losses in the armature winding +P losses in the separately excited field winding

Output Wattage = kVA x cos qInput Wattage = kVA x cosq+ Copper loss + Stray loss

Stray loss = Bearing and brushes friction losses +

Windage losses + Iron losses ( eddy current

+ hysteresis losses )


Performance


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Fuel (Chemical Energy)

Mechanical Energy Input

(Engine Power)

p.fGen + Load

KVA

(Mechanical Energy Input)

Motor Hp rating

KWinput

(Mechanical Energy Output)

Overall Performance

KWout



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Brushless AC Generator

Main Parts and Function

Main Generator

Rotating Rectifier

AC Exciter

AVR

No slipring and carbon Brush required

Less Maintenance

has PMG for high KVA rating as

an additional components


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Parts and Function1 The Main Generator

4-pole, rotating field ac generator

The field winding is wound to the salient pole of the rotor

Speed at 1500 rpm

415VAC, 50Hz output is tap from the stationaryarmature winding.


Cylindrical PoleSalient Pole

Field Winding

Rotor Body

Inter-connectorPole Shoe


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Parts and Function2 The AC Exciter

> 8-pole brushless stationary field ac generator

provide high armature output @ >100Hz frequency to be rectifiedand converted to DC voltage by a rotating rectifier for main

generator field excitation.



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Parts and Function3 The Pilot Exciter

an AC generator with rotating permanent magnets as its field.

provides constant power to the AVR/MVR under all conditionsregardless of the main generator output condition.

For high KVA rating only >1MVA


Permanent Magnet

AC Exciter Armature


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Parts and Function4 Automatic Voltage Regulator (AVR)

to control and regulate DC excitting current to the Exciter Field

consist of Rectifier circuit, Voltage regulator/adjuster/comparator

and Amplifier


AVR

Main

Generatorwinding

Ac Exciter

Field

Main GeneratorField

Rotating rectifierAc ExciterArmature


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Parts and Function5 Rotating Rectifier

a three-phase full-wave bridge, having six diode elements, mountedon a rotating steel plate, located at the exciter end for easyinspection, testing and replacement.

output of ac exciter is rectified and converted to DC excitationvoltage here for main generator field excitation.



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Generator Excitation


Self excited,Brushless

Rotating coil stationary field

Three phase generator


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Generator Excitation



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Self excited,Brushless

Rotating coil stationary field

Three phase generator


Generator Excitation (with Pilot Exciter)


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Generator Excitation (with Pilot Exciter)

AVR

Permanent Magnet

Rotor

Exciter

Rotor

Rotating rectifier

Assembly

Main field

Shaft Axis

Permanent Magnet

Stator

Exciter

Stator

Main Stator

Output

Terminals


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Local Control Panel

start and stop the engine from the engine skid.

provide general fault indicating lights.

monitor engine speed

Function


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Generator Board

for start and stop the generator set.

continuous display and monitoring of the generated output.

provide generator protection facilities with audible alarm signal

and fault indication lights.

provide generator circuit breaker control .

provide control engine speed, generator excitation/generator voltage.

provide provide synchronization facilities.

Function


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Generator Board

Parts

B - Busbar Metering Panel

D - Synchronizing Metering Panel

F - Neutral Isolator Panel

A - Generator Metering Panel

C - Generator Protection Panel

E - Power Factor Circuit Breaker K - Generator Circuit Breaker

L - Load Circuit Breaker

G - Circuit Breaker Control Panel

H - Synchronizing Panel

I - Load Metering Panel

J - Power Factor Correction Panel

A AB B CD D E

FG

H

F

G

I

J

K K L

M MN N

P P OQ Q

N - Engine DC Control Panel

M - Neutral Contactor Panel

P - Battery Charger Panel

O - Lightning Arrestor Panel

Q - SpecialTool Compartment


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Generator Board

The 3 Systems

VITAL in ensuring the integrity and continuity of a supply.

PM G

Control System

Protection System

Metering System

Busbar


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Generator Board

1. Metering System

to monitor system performanceline voltage, line current,power factor,reactive power , true power ,frequency andpower consumption rate.

tap to the main line through Potential transformer (P.T)or/and through Current transformer (C.T).

links together with indication devices: indicating lights


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Generator Board

1. Metering System Connection


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Generator Board

2. Control System

to control the generator operation and performance

smooth start-up (auto and manual)

regulates the speed and voltage output (Governor and AVR)

synchronizing if possible


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Generator Board

2. Control System (Electronic Governor)

provides two functions, indicate exact engine speed andkilowatt load sharing when synchronised

Electronic

Processor

and

Amplifier

Actuator

Engine Generator

Fuel line

Magnetic Pickup

Engine Flywheel

Input from Auto Synchronizer

Input from manual

Speed TrimmerFuel Control Valve


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Generator Board

2. Protection Systemprotects the generator against system problems/faults

overload, loss of load, unbalanced loading,

under/over frequency and under/over voltage,

Insulation failure,

mechanical failure,

excitation system failure

reverse power


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Generator Board

2. Protection System Connection


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Generator Board

2. Protection System (Alarm & Shutoff)DC CONTROL SWITCH

SR

AST

MANUAL

START P/B

AFR-3

SR-4

FSM-4

FSM

SDT-1

AFR-4

OPT

FC-4

FC

FSR-1 EFR-1 OCR-1 RPTR-1 LOP-1 HWT-1 OSR-1

ACR

ARFC-2

ALARM CANCEL P/B

ACR-2

ACR-1

FSR-2 RESET P/B

FSR

FST-1

EFR-2

EFR

EF-1

OCR-2

OCR

OC-1

RPTR-2

RPTR

RPR-1

LOP-2

LOP

OPT-1

HWT

HWT-2

OSR

OSR-2

Alt-Relay No Contact

ive

EMERGENCY STOP

to warn the operator that anunsafe operating condition is

occurring.

Remote switches deenergiseFC relay cause the engineshutdown

Alarm Bell continually sounduntil reset button is pressed.


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Charger and Battery Bank

provide a DC supply to Starter Motor for engine cranking.

Function

Static Charger

Rotary ChargerStarter Motor

Battery Bank

Governor Actuator


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Fuel Storage

Function (Bulk Storage)

to ensure continuous and clean supply of diesel fuel.

intake line


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Auto Main Failure Board (AMF)

Functionprovide permissive to start signal to the generator set via

undervoltage relay

to do 'supply to the load' switching either from mains or fromgenerator.

connect/disconnect the generator to/from the essential/vital

switchboard. From GeneratorBoardFrom

MSB

To Ups and VitalSwitch Board


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Sequences of OperationUnder Voltage Relay (set at 80-90% of rated voltage) detects loss (or

abnormal reduction) of voltage.

Permissive to start signal activates the starting of the engine (after 2-3sec delay to confirm real power lost ).

Energising of the starter motor system (take about 1-2 secondintervals for the starter pinion to engage).

Full power cranking, an engine speed detection circuit indicates whenthe engine has fired and has started to run up to speed and at thispoint the starter motor is de-energised and locked out.

Acceleration of the engine/stable generator output. A few seconds is

needed for the generating set is deemed ready for load transfer.(Synchronized if possible the system can take-up the loads.)

Energising of Neutral Contactor and closing of generator CB.


In Auto-mode, it normally take 20 sec to complete the whole process.


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Overall Interconnection


CB2CB1

Prime

Mover

Gen.1AVR

Gen.1

LocalControl

Unit

Metering &

Protection

CB1

Control

Unit

Gen.1

Remote

Control

Unit

Gen.1 Static

Charger

Prime

Mover

Gen.2AVR

Gen.2

LocalControl

Unit

Metering &

Protection

CB2

Control

Unit

Gen.2

Remote

Control

Unit

MUVR@AMF

240V Supply from MSB

Auto Start

&

Synch

Synchronizer

&

Load Sharing

Module

Main Healthy

to AMF Board

P.F

Correction

Unit

Built-in

Rectifier

Rotary

Charger

Battery

Bank

StarterMotor

Governor

& Speed

Sensor

Prime

Mover

Gen.1 Static

Charger

Rotary

Charger

Battery

Bank

StarterMotor

Governor

& Speed

Sensor

Built-in

Rectifier


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Manual Start-up Procedure


A) Entering the Generator Room.

wear complete safety gears; coverall, hard hat, boot, earplug/ear guard and goggle.

ensure that the room is safe to enter by referring to the roomcondition indicating light (Green), open the main door, let thedoor open for a while to ensure all the gas inside the room ispurge out.

ensure the light is enough, the availability of fire extinguisher,single line drawing and rubber mate inside the room.

sign and record the intended activities in the record/log book.


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B) Before operating the generator

ensure fuel for diesel engine is at operating level and both valvesfor fuel inlet and return line are in open position.

do inspect on Diesel Engine

Battery bank voltage at minimum of 24VDC

Radiator water level at operating level

Lub oil at operating level and no leaking

Any loose items on top of the engine

C) Before operating the panel, ensure all breakers and switches are

in OFF position.


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D) Follow the procedure and refer to attach DC Control single line drawing.

Put DC Control switch to ON position and DC Selector Switch to manualposition .

Release the Emergency Stop button.

Press START button .................. Prime Mover will start.Monitor generator metering panel.

- Adjust voltage and frequency using voltage trimmer andspeed trimmer to a required Value ( V= 415V, f= 50 Hz ).

Put a circuit breaker switch to manual mode.

Release circuit breaker Emergency Trip button.

ON Neutral Contactor or Close Neutral Knife Switch.

Press circuit breaker ON Push Button...........Circuit breaker will close.


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Manual Shutdown Procedure


E) Follow the procedure and refer to attach DC Control single line drawing.

Open generator circuit breaker by pressing 'OFF' push button

Press generator circuit breaker Emergency Trip Push Button to disableclosing of the circuit breaker electrically

Switch 'OFF' generator Neutral Contactor Switch of 'Open' Neutral Knifeswitch

Turn the generator circuit breaker Mode Switch to 'OFF'

Press 'Emergency Stop' push button to disable starting the generatorprime mover electrically

Turn Duty Selector Switch to 'OFF'

Turn DC Control Switch to 'OFF'

In general, shut down procedure is reverse the start-up procedures unless

emergency shutdown required by pushing the emergency push button

sync generator example

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