16

5.

CONTROL SYSTEM

The WD Power Plant control systems are built for

Basic, Classic Extended, Extended and
Advanced automation concepts. Each level
requires different features to be verified.

Fig.5.3: Extended level automation systems are

based on Programmable Logic Controllers for
monitoring in central operator stations, WOIS and
on local control panels. Other features include
extended
instrumentation,
automatic
load
reduction, automatically produced reports and
optional start/stop sequences.
Fig.5.1: The Basic level control systems are built
using conventional central control panels for
manual control and relay based logic.

Fig.5.4: Advanced level automation system.

Fig.5.2: Classic Extended level automation

systems are based on Programmable Logic
Controllers for monitoring in central operator
stations, WOIS and on local control panels. Other
features include basic instrumentation and
automatic load reduction.

The Advanced level introduces new technology as

integrated WECS (Engine Control System) and
bus-connected distributed PLCs for process units
and switchgears, full sequence controls and further
increased instrumentation.

17
5.1 General
Good, low-impedance earthing is essential for any
kind of low-level signal handling system. Pay great
attention, therefore, to good earth binding of
control panels, desks, free-standing power supplies
and PCs / terminals with peripherals. Modular
desks and panels should be reliably bound
together and furnished equipment bound to the
frame with dedicated terminals wired to PE
terminal blocks or bars.
Check from the installation manual that the
earthing / screening diagram has been strictly
followed using low-impedance bindings and that
there are no unintentional connections or leaks
connecting different earth-bound systems.

5.2 Inspection of installation

An initial inspection should be made to ensure that
all desks and panels are located and fastened
correctly, that they are in no way damaged, and
that any separately delivered devices have been
correctly installed in the panels or desks.
Interconnections between sections of desks/panels
delivered as separate parts should be checked for
complete and correct terminations.
Check that all cable installations have been
properly made, using internal routing and fastening
as intended by the desk/panel manufacturer. Pay
special attention to signal cable terminations,
ensuring that (<100V) signal-voltage insulated
cores are not close to or in contact with cores or
hook-up wires carrying higher voltages. Check that
screens of signal cables are isolated from the
frame, that cable screens are connected to
eart/ground system, and that pair-screens are
connected to a TE termination strip for treestructured screening. Check also that desk / panel
PE and frame are firmly bound to the station earth
in accordance with the appropriate earthing system
drawings.

The control system should be connected up,

energised and made functional as early as possible
in order to enable full-scale testing of distributed
units including remote alarms and controls. This
may mean that a computerised control or even
some type of PLC system will need a temporary
AC supply until normal low voltage distribution is
operable. Take special care to avoid damaging
apparatus or coming into contact with live parts
due to temporary connections.
Complete functional tests cannot be performed
until all distributing and auxiliary units and devices
are installed, set up and tested for full functionality.
You can still avoid double testing by setting up the
indicating, alarming and reporting systems for
separate signals to be tested when testing
distributed systems.
control, remote control and synchronising circuitry
must not be energised before switchgears and
local panels are tested.
Test indicator lamps using the Lamp Test facilities,
and adjust or repair loose or faulty lamps.
Uninterrupted Power Supplies (UPSs) intended for
supplying supervisory computers, printers etc.
should be connected as intended to limit
interference from power distribution and not
damage this sensitive equipment. Check for correct
nominal voltages / voltage settings of controllers,
monitoring and peripheral devices before
connecting to power distribution. All communication
and signal interconnections should also be made
and secured before connected devices are
powered up.

If the control system includes a monitoring / data

acquisition system, this part of the system should
also be fully set up.

Power up and start logic controllers and data

acquisition / monitoring systems by installing and
starting all programmes needed for linking signals
to screens and printers. Load complete and
finalised
application
programmes
before
performing any functional tests. Note that only
software applications especially developed and
functionally tested for this specific project are to be
installed. No applications, however excellent,
developed at a previous site are allowed as they
will not have been factory tested against these
connections.

5.3 Powering up

5.4 Basic and function tests

Insulation tests are recommended to be performed

for large control voltage distributions before the
voltage is connected. Check that the voltage and
polarity are correct before closing any distributing
MCBs. At this initial stage, auxiliary voltages
should be connected only to systems which are
necessary for registration of incoming signals, such
as alarm signals and state-indications. Engine

Test that central and distributed alarm acquisition

systems function with both supplies (if doublesupplied). Check that internal fault / supply
watchdogs produce external alarms. Check that
sounds/flashes are functional and re-settable as
intended. Check that jumper, display or PC
programmable systems are marked up and initially

18
programmed for correct signal types, delays, alarm
levels and grouped relaying to sound/flash and
remote alarms. A signal-specific check should be
made as soon as installations are complete,
systematically checking through each connected
signal.
Check that the monitoring system, PLC and UPS
faults actuate the correct system fault alarms in the
local / remote alarm system by simulating power,
communication interrupts and other similar faults.
Any system check facilities provided by control
software / hardware should be run to check for
system faults. Set the monitoring system / PLC
clocks to the correct date and time. Test that event
and alarm reporting is functional by simulating a
signal on some connected circuit. Watchdog
checks and program running indications should
indicate full functionality before now proceeding to
testing connected systems and circuits.
While testing other parts of the entire controlgear,
you will have to return to the centralised control to
check those parts of tested circuits which are
located in the desk/panel and also to check alarms
and indication signals transferred to these desks/
panels.

5.5 Control circuitry tests

As soon as substation connections, MV, LV
switchgears and local panels are under control and
will not cause danger even as a result of a false
command, the control circuitry should be tested.
Power up internal control circuits through shortcircuit and polarity checks. Test DC controlled
circuits for synchronisation, interlockings, feeder
switching etc. circuit by circuit as described in
Commissioning practice. You can test the PT
secondary voltage circuitry for supervision /
interlocking and even for voltages connecting up to
synchronising equipment at the same time by
performing the test when the voltage is set to the
MV switchgear.
You will need a relay tester and a calibrated mA
DC supply to check metering signals and for
indication tests. Test control desk / panel MW, PF
and MVAr indicators with circuitry and screen +
recorder indications by injecting 4 mA and 20 mA
DC signals at temporarily disconnected transducer
outputs. Volt, double volt and frequency meters are
tested by injecting 0...110 VAC into these circuits
at disconnected PT-MCBs. Note that 110 VAC
injected into the PT secondary will produce full
primary voltage on the primary terminals, thereby
causing a danger to health and PT damage.
Ammeters are tested by injecting 5A AC current
into CT secondary circuits from which the CT
secondary windings are disconnected.

For PLC and monitoring systems an I/O test should

be performed: Test each input signal not fully
tested as previously described by secondary
injection from the field, checking the signal at the
1st termination, the I/O card, PLC screen, PC
screen, printer alarms and interlocks. Test each
output signal from the PC/PLC screen to the field
connection.
Each of these tests and associated functions must
be recorded on test record sheets. All lists and
displays available from the PLC and the PC should
be printed / plotted and these hard copies should
be attached to the test records.

5.6 Power monitoring unit PMU

The function of PMU is based on three phase
voltages and current measurement. Thus three
phase measurement is required for both voltage
and current. All the measured quantities are
displayed as primary values, that is the values
shown on the display are real process values.
The PMU measures following:
-Phase to neutral and phase to phase voltages
-Phase currents
-Frequency
-Power factor
-Active, reactive and apparent power
-Active and reactive energy
-Total harmonic distortion (THD)
-Harmonics
Before connecting PMU, check that the rated
values of the device correspond to the actual
values of the application. Especially check the
auxiliary voltage and the rated current of the
device. The rated values are found on the front
panel of the device.
The input and output circuits are wired to the
terminals on the rear panel. The terminals are
detatchable, except for the current terminals.
All cables must meet the general requirements for
cross-sectional area. The auxiliary voltage circuit
must be equipped with a proper two-pole switch
and a maximum 10 A fuse. These should be
placed near the device.
The device must be earthed to the earthing
terminal of the rear panel with an earthing
2
condutor of minimum 2.5 mm .

19
generating set control
auto
engine
start
Starting sequence:
Starts engine to off line
Automatic synchronisingby the PLC
Loading toremote reference level (MMI)
Cancels STOPorder

manual

Engine control:
kWenableinGRID,
Isoch enable in Island
Generator control:
P.F. enable

engine control

stop
Stopping sequence:
Automatic unloading
Automatic breaker open
2 minutes off line running
Stop

speed

kW/isoch

voltage

pf

droop

kWin Grid, Isoch in Island

droop

pf in Grid, Droop in Island

fuel

excitation

increase decrease

breaker

fig.5.6. The front panel of the PMU

1 LCD dot matrix display
2 Key pad
3 Function indicators:
Power
auxiliary supply on
Run
program running
Error
self-supervision fault, parallel
indication obtained with selfsupervision output relay
Program
switched on when the program is
loaded via the serial port and when
parameter values are stored in the
non-volatile memory
Serial Com indicates serial communication activity
A, B, C, D application-related status indications
4 RS 232 serial port for connection of a PC
The basic parameters needed in typical
applications can be set through the local panel.
But, settings of certain parameters requires the
VEPSET software. If the software is not available,
PMU can be configured by manufacturer when
ordering.

closed

open

Dead bus closure

OPENS BREAKER AT ANY

RUNNING SITUATION

generator control

engine
start

Starts engine to off line

increase

synchronising

stop

Stops engine when the

breaker is open

The figure above shows a selection diagram of the

Main control unit.
The main control unit contains following:
Switches
S1
S2
S3
S4
S5
S6

generating set control

auto - manual
engine control
speed droop - kW/Isoch
generator control
voltage droop - pf
fuel
decrease - increase
excitation
decrease - increase
synchronising
0 select/start

Light (indication) push buttons

S7
S8
S9
S10
S11
S12
S13

engine start
engine stop
breaker close
breaker open
engine shutdown reset
breaker trip reset
lamp test

5.8 Generator protection relay

5.7 Main control unit
The main control unit allows the operator to take
manually control of the engine. To get that to work
you will need to select the generating set control
switch (S1) into manual position.

The protection relay provides a wide range of

protection, metering and monitoring functions and
is used for for small and medium size generators.
The generator protection relay offers flexible earth
fault protection features for both single and parallel
connected generators. The fully numerical design
of the relay allows exact settings and accurate
measuring for generator protection functions.
The potection relay has following protections:

fig.5.7. main control unit

- 2 stage overcurrent
- 2 stage earth fault
- Reverse power
- Over/underfrequency
- Over/undervoltage
- Unbalance
- Underreactance

decrease

select/start
Initiates manual
synchroinising
Actual synchronising is
made at common section

20
The figure 5.8 shows a typical connection of the
protection relay.

From the picture above you can see the genset

output power on P-Q diagram and reverse power
trip regions and loss of exitation.

fig 5.8. Protection relay