GI & GIII GENERATOR CONTROL PANEL

INSTALLATION, OPERATING & MAINTENANCE MANUAL

SEREPT

ORDER No. 20-0 679

ASHTART REVAMP PROJECT

ACTEMIUM REFERENCE IWO 8254

INDEX

1. Health and Safety Instructions.

2. Panel installation instructions.
3. List of Drawings for Generator Control Panel.
4. Sequence of Operations, Recommended Settings and Maintenance.

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1.0 HEALTH AND SAFETY INSTRUCTIONS

1. Compliance with instructions in this manual

The purchaser/user is advised to comply with the instructions and information given in this manual and
ensure that all personnel to be associated with the apparatus supplied under this contract are made
familiar with the information contained herein.

2. Installation
The purchaser/user should ensure that the apparatus supplied under this contract is correctly installed in
a suitable location by technically qualified and competent persons.

Apparatus supplied as loose components, devices or subassemblies could, when energised, constitute a
safety hazard. The purchaser/user should ensure that such apparatus is installed in a secure location and
that adequate safety information about the installation is provided to all personnel to be associated with
it.

3. Operation and Maintenance

3.1 Guidance Notes for Users on the Safety of Personnel

The rules for ensuring the safety of personnel can be summarised as follows:

(a) During Normal Use ensure that the plant operators:

- are fully conversant with all controls, particularly those for emergency shutdown

- comply with safety warning notices and keep all enclosures shut

- are trained to recognise signs of maloperation and know what action to take in the event of
trouble or difficulty.

(b) During Maintenance, Testing etc ensure that only technically competent and authorised persons
are permitted to carry out work and that they:

- comply with statutory requirements

- are fully conversant with the apparatus and the system of which it is part, and recognise hazards
which could arise, eg back feed.

- isolate the apparatus completely, where possible before opening enclosures and prove it to be dead
before starting work. Precautions must be taken to ensure that the isolated apparatus cannot
become live whilst any work is being carried out.

- comply with any safe working procedures for the safety of themselves and of others including the
use of temporary barriers and warning notices

- are conversant with the information provided, particularly on measures relating to safety.

- recognise the hazards which can arise when working on live apparatus and take all the necessary
precautions.

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 - functionally check the apparatus and then mechanically and/or electrically test it in accordance
with this manual and good working practice before putting the apparatus back in service.

- take account of the possibility that the apparatus may have been modified without proper
reference to the manufacturer and take extreme caution at all times before, during and after any
work is carried out.

If there is any doubt as to the correct and safe method of working, then further assistance should be
sought from ACTEMIUM.

3.2 Skills Required for Specific Tasks

To ensure that under normal healthy plant operating conditions the plant is safe to use:

- it has been designed and tested in accordance with relevant British, European and International
Standards.

- information is provided in this manual about the conditions necessary for safety and about any
hazards which are reasonably foreseeable during normal use, together with precautions to be
taken to counteract them.

However, the Purchaser/User should ensure that the apparatus is maintained in a safe condition and
if technically competent and authorised personnel have to gain access to apparatus which is not made
completely safe as recommended, everyone under whose authority these persons act should ensure
that appropriate safety procedures are generated and are complied with.

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Reference to the MINIMUM SKILL LEVEL REQUIRED FOR
Apparatus/Task/Skill Level
Schedule below enables the user to
select personnel to carry out
specified tasks requiring access to
the apparatus.
Grade Degree Of Integral 100% Isolation Setting, Cleaning & Setting, Cleaning & Special Testing
Isolation Provided For & Proving Dead Routine Routine Commissioning
Maintenance Maintenance Fault Finding

WITH POWER WITH POWER ON WITH POWER ON

OFF 100% OR NOT 100% OR NOT 100%
ISOLATED & ISOLATED ISOLATED
PROVED DEAD

1 100% Isolation by C A C C
operation of the
isolator(s) provided
2 Partial isolation only by
operation of the
isolator(s) provided. The C A C C
Purchaser/User is
responsible for 100%
isolation elsewhere

3 No isolator provided.
The Purchaser/User is C B C C
responsible for any
necessary situation
elsewhere

4 100% Isolation not

possible because Not applicable Not applicable C C
Impracticable
Unreasonable
and/or Undesirable

5 Apparatus supplied as
loose items, Skill level to be
subassemblies etc for C determined by the C C
which the Purchaser/User
Purchaser/User is
responsible for wiring,
assembly etc. (See page
1 paragraph 2)

SKILL LEVELS AS REFERRED TO IN THE SCHEDULE ABOVE

SKILL JOB DESCRIPTIONS

LEVEL Proposed by Supplier User
A Operating and maintenance staff with NO electrical
knowledge but fully conversant with the operation and
maintenance of the apparatus
B Maintenance staff with SOME electrical knowledge and
fully conversant with the operation and maintenance of
the apparatus and the system of which it is part
C Authorised and competant staff (eg Electrician,
Commissioning Engineer) with HIGH degree of
electrical expertise; trained to work on live apparatus
and fully conversant with the operation and
maintenance of the apparatus and the system of which it
is part

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2.0 INSTALLATION INSTRUCTIONS

Align the panel against the enclosure wall fixing holes using suitable forklift truck or overhead
crane by use of the panel lifting eye bolts. Great care should be taken if using a forklift truck as the
panel is top heavy and maybe unstable.
Fix the panel to the enclosure wall using bolts of a suitable length.

The Generator Control Panel is arranged for bottom cable entry through removable undrilled gland
plates. On completion of the cabling installation, a visual check followed by a continuity check that
all cables are installed in accordance with the wiring/schematic diagrams is required.

3.0 LIST OF DRAWINGS - (C05-1001 Pages 1 – 52).

3.1 Drawings for Generator Control Panel GI & GIII

Pages 1-2 Drawing schedule for GI & GIII

Page 3 Notes for GI & GIII

Page 4 Component Chart for GI & GIII

Pages 5 General Arrangement for GI & GIII (front view)
Pages 6-7 Internal Arrangement & Seating details for GI & GIII

Page 8 Single Line / Block Diagram for GI & GIII

Page 9 220V AC & 24V DC Supply Circuits for GI

Pages 10-11 Excitation Circuit for GI

Page 12 Metering, Instrumentation Circuits for GI
Pages 13-15 Digital Integrated Generator Protection Relay Circuits for GI
Page 16 Digital Integrated Generator Protection Relay Matrix for GI
Pages 17-18 Control Relay Circuit Diagrams for GI
Page 19 Indication Circuit Diagrams for GI
Page 20 Synchronising Circuit Diagrams for GI
Page 21 Circuit Breaker Open/Close Control Circuits for GI
Page 22 Governor Control Circuit for GI
Page 23 220V AC Control Circuits for GI

Page 24 Volt-Free Circuits for GI

Pages 25-30 Terminal Layout for GI

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Page 31 220V AC & 24V DC Supply Circuits for GIII
Pages 32-33 Excitation Circuit for GIII
Page 34 Metering, Instrumentation Circuits for GIII
Pages 35-37 Digital Integrated Generator Protection Relay Circuits for GIII
Page 38 Digital Integrated Generator Protection Relay Matrix for GIII
Pages 39-40 Control Relay Circuit Diagrams for GIII
Page 41 Indication Circuit Diagrams for GIII
Page 42 Synchronising Circuit Diagrams for GIII

Page 43 Circuit Breaker Open/Close Control Circuits for GIII

Page 44 Governor Control Circuit for GIII
Page 45 220V AC Control Circuits for GIII

Page 46 Volt-Free Circuits for GIII

Pages 47-52 Terminal Layout for GIII

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4.0 SEQUENCE OF OPERATIONS RECOMMENDED SETTINGS & MAINTENANCE

Refer to drawings C05-1001 Pages 1 to 52 whilst reading the following Sequence of Operations.

1.0 General Description

The Generator Control Panel provides Instrumentation, Excitation Control and Synchronising for
Two Gas Turbine Generator Set.

The Excitation Control is carried out by the Basler DECS 200 voltage regulator.

The Synchronising can be carried out manually via an DEIF Check Synchroniser or automatically
by DEIF Auto Synchroniser.

2.0 Circuit Operation

2.1 Excitation Instruments:-

'AF' This is a moving coil ammeter which provides indication of the field current.
'VF' This is a moving coil voltmeter which provides indication of the field voltage.

2.2 Generator Heater Contactor Control:-

GHC Alternator Heater Contactor is de-energised when the Generator Circuit Breaker is open
by contact KA8.1. Contact GHC will be closed to connect the 220V AC supply to the
Generator Heater. When the Breaker is closed, the heater will be disconnected.

2.3 Excitation Control

For details, refer to Basler Manuals.

2.4 Metering

The instrumentation and metering for the generator operates from remote voltage and current
transformers. Transducers are included to provide 4 - 20mA signals for remote monitoring.

2.5 Synchronising

Manual and Automatic Synchronising are provided for the Turbine Generator circuit breaker.

2.5.1 Generator Auto Synchronising

When Automatic Synchronising is to be initiated, selector CS7 should be placed in 'AUTO'

and CS10 in 'LOCAL' positions. Contacts on this switch enable operation of KA9 relays.
On operation of PB2 (Auto Synchronising initiate pushbutton), relays KA9 energise. Contacts
on KA9 operate:-
Closes to energise KA12 relays.
Closes to retain the KA9 relays.
Opens to initiate the auto synchroniser 25A.
Closes to connect the speed control contacts 25A-SR and 25A-SL to the Governor.

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Contacts on KA12 operate:-
To connect 25A-BC (Auto Sync) and 25C-BC (Check Synchroniser) to the
Generator Circuit Breaker Close circuit.

The Auto Synchroniser (25A) being connected, will commence to operate. Its Voltage Control
contacts 25A-VL and 25A-VR will operate to make the Automatic Voltage Regulator match
the Generator Voltage with that of the '5.5kV' buswire.
Its Speed Control contacts 25A-SR and 25A-SL will operate to bring Generator into
Synchronism at which point contacts 25A-BC will operate together with Sy-BC to energise
the Circuit Breaker Close circuit.
Following Breaker closure, contact KA8.1 opens to de-energise KA9 relays to reset the
circuit.
The selector CS7 should be left in the 'OFF' position following synchronising completion.

2.5.2 Generator Manual Synchronising

When Manual Synchronising is to be carried out selector CS7 should be placed in the
'MANUAL' position. Contacts on this switch energise KA12 relays. Contacts on KA12
operate:-
Closes to connect the busbar VT to the 5.5kV Buswire and Generator VT to the
'GENERATOR' buswire. The synchronising instruments and synchroniser are now
connected to the 'generator' and '5.5kV' bus wires.
To connect Sy-BC (Check Synchroniser) to the Generator Circuit Breaker Close
circuit.
CS9 Generator Circuit Breaker OPEN/N/CLOSE control switch is used to close the
Generator Breaker. The 'OPEN' position is always operable.

CS3 and CS4 - Voltage control and Speed adjustment control switches are used during
'MANUAL' synchronising.
The synchronising instruments Vs, Hzs and S together with the check synchroniser (Sy) will
be connected to the 'Generator' and '5.5kV' busbars.
The 'Generator' voltage should be adjusted by the Lower/Raise switch CS3 until it matches the
'Running' voltage.
The 'Generator' frequency should be adjusted by the Lower/Raise switch (CS4) until it
matches the 'Running' frequency. When the 'Generator' & 'Bus' voltages and frequencies are
nearly the same, the Synchroscope (Sy) pointer should become virtually stationary in the
vertical position. The Check Synchroniser contact Sy-BC will be closed at this point which
will enable CS9 control switch to close Generator circuit breaker.
The selector CS7 should be returned to the 'OFF' position following synchronising
completion.

2.5.3 Failure to Synchronise

Following Auto Synchronising initiation, relays KA9 energise.

Auto synchronising timer relay KA9 energises for a period of 180 seconds during
which time synchronising should have taken place. On failure of the generator to
synchronise, contact KA9 will remain closed and KA9 contact will operate after
180 seconds.
Contact KA9 will open to de-energise KA10 relay.

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 Failure to Synchronise relay KA10 contacts operate:-
Opens to prevent retention of KA10 relay.
Opens to de-energise KA9 relays whose contacts in turn operate to disconnect 25A
(Auto Synchroniser) and prevent further Auto synchronising.
Closes to illuminate indicating lamp SL3.

2.5.4 Dead busbar synchronise control

This circuit operates to enable the generator circuit breaker to be closed when the busbar
is dead.

CS8 (Dead Bus Enable Switch) should only be used in exceptional circumstances. It is
important that the key to operate this switch is permit controlled to prevent unauthorised
operation. The switch is used only for the following circumstances:-
(a) When the check synchroniser has failed.
(b) To enable manual close of a circuit breaker when the bus is dead.

Two safeguards are provided with the switch:

(i) It is key operated to prevent unauthorised
(ii) It has a spring return to OFF action.

If the busbar is dead when the generator breaker is being manually synchronised, the circuit
operation is as follows:

KA100 will be de-energised when the busbar is dead. Its contact will be closed to
make CS8 effective. CS8 and CS9 are used by the operator to close the generator
circuit breaker.

2.6 Protection Relay

Refer to the Generator Protection Tripping Matrix for relay inputs and outputs.
Reference should be made to the relevant publications for details of its operation.

3.0 Recommended Settings

Timer KA9 at 180 seconds
Auto & Check Synchronisers - Refer to the DEIF publication for settings.

4.0 Maintenance

Refer to the relevant publications for the AVR equipment, check and auto synchronisers for their
recommendations.

The equipment included within the panel is virtually maintenance free, however, the following is
recommended:-

A Avoid the build up of dust within the panel by cleaning with a soft brush and a vacuum cleaner.

B Visual check of components with particular attention paid for signs of scorching or burning.
This should be carried out on a monthly basis.

C Check on a monthly basis that the panel anti-condensation heater is operating.

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