2 DGS WITHOUT SYNCHRONISATION

This document describes the PLC logic for 2 DGS & 1 EB incomer in non synchronization panel and
its sequence of operation, the PLC configuration & required inputs.
 2020

Overview:

In general when EB power is available the total load is supplied by the EB (Electricity
board), the DGS will remains off. When there is no EB power or EB power is
unhealthy then DGS should get on immediately & should start supplying the load.
This can be done by using a PLC, PLC detects the EB power status with the help of
digital inputs and controls the DGS, their breakers & outgoing breakers with the help
of digital outputs. If EB power is restored or it is healthy, then the DGS automatically
will get OFF & and load supplied by the EB.

When the DGs are not in synchronisation, then the Busbar is divided into no. of
isolated sections equals to n-1 (n = no. of DGs). And these sections are coupled with
ACB’s (Bus-coupler).

When two DGs are running then Bus-coupler will be in open condition and if only one
DG is running or load supplied by EB then Bus-coupler will be in closed condition.

Generally in the 2 Generators, one will be master and another will be second. If in
case of total load on 2 DGs is less than 65% of rating of master generator, then
second DG will be turned off and Bus-coupler will be closed & the section 1 and 2 are
supplied by only one DG (master DG). The master selection can be done by an
external selector switch or we can implement automatic selection in the PLC logic or
if we have HMI in our project, can be selected through HMI.

To measure the load on a DG we are using Multi Function Meter (MFM). This MFM
supports the MODBUS RTU communication & we can communicate PLC with this
MFM through RTU and therefore we can read the KW, KWH, line current (amps), line
voltage (volts), power factor, frequency, etc.

(OR)

We can use 4-20 ma analog modules with analog transducer which gives 4-20 ma
output & which further connected to a current coil. We need to scale values in PLC

Page 1
 2020
according to current coil rating. But this type set up increase cost & also makes
control panel bulky.

Note: Please refer the logic pdf for more info about two load measuring methods.

So we can get the load current on a DG and so that we can get total load on the 2
DGs. it will be compared with the DG rating so that the PLC will decide whether 2
generators need to run or one is enough. Thereby we can save fuel on low load
conditions.

Figure 1: Two DGs & one EB incomer without synchronisation

Page 2
 2020
On the above schematic diagram you can see interlock between DG breakers, EB
breaker and Bus-coupler. This interlock should be implemented in the PLC logic. In
case of without interlocks between these breakers, there will be a chance of short
circuit between 2 DGs or 2 DGs & EB, which will lead to damage of DGs and other
equipment.

ACB  Air Circuit Breaker, used to protect generators from overload, short circuit
faults & isolate generators & EB incomer from the bus bar. This breaker comes with
spring charged motor mechanism. There are separate springs for opening and closing
of breaker. The motor is controlled by limit switch in the breaker.

Bus-coupler is an ACB, which is used to connect 2 isolated busbar sections. A Bus-

coupler is more pronounced in DG logics where there is no synchronisation between
two DGs. Because if DGs are on & Bus-coupler is on then the 2 DGs will get short
circuited. And if only one DG is on and Bus-coupler is off then one of the section
won’t get power. And the loads connected to that bus section will experience power
cut.

Page 3
 2020

Figure 2: open view of an ACB

PLC configuration

 Simatic S7-200 smart CPU ST30 (it depends on no. of DGs, this is minimum
configuration).
 EM AE04 (4AI) analog input module (if not using MFM).

Page 4
 2020

Figure 3: PLC configuration

IO LIST:

NAME OF THE INPUT ADDRESS

EB VMR HEALTHY I0.0
DG1 VMR HEALTHY I0.1
DG2 VMR HEALTHY I0.2
EB ON STATUS I0.3
DG1 ON STATUS I0.4
DG2 ON STATUS I0.5
BUS COUPLER ON STATUS I0.6
EB OFF STATUS I0.7
DG1 OFF STATUS I1.0
DG2 OFF STATUS I1.1
BUS COUPLER OFF STATUS I1.2
AUTO_MANUAL OF ALL I1.3
EB ANALOG TRNSDUCER AIW16
DG1 ANALOG TRNSDUCER AIW18
DG2 ANALOG TRNSDUCER AIW20
NAME OF THE OUTPUT ADDRESS
EB CLOSING COIL Q0.0
EB UNDER VOLTAGE COIL Q0.1
DG1 ON CAMMAND Q0.2
DG1 CLOSING COIL Q0.3
DG1 UNDER VOLTAGE COIL Q0.4
DG2 ON CAMMAND Q0.5
DG2 CLOSING COIL Q0.6
DG2 UNDER VOLTAGE COIL Q0.7
BUS CLOSING COIL Q1.0
BUS COUPLER UNDER VOLTAGE COIL Q1.1

Page 5
 2020

Sequence of operation:

1. When EB power is available & healthy, EB breaker will get closed & two DGs
and their breakers will be in off condition.
2. And after 10 seconds Bus-coupler will get closed (first after 5 seconds under
voltage coil will be activated & after 5 seconds closing coil will be activated
thus breaker will be closed), total load will be supplied by the EB only.
3. When EB is off or faulty, then two DGs will on immediately, after getting DG
VMR signal, EB breaker off status, one of the DGs breaker will be closed by the
PLC after 10 seconds. If there Bus-coupler off status, Next DG breaker will be
closed after 10 seconds.
4. DG1 supplies outgoing-1 (bus-1) and DG2 supplies outgoing-2 (bus-2).
5. If the total load on two DGs is less than the 65% rating of master DG, then
secondary DG will turn off after 5 minutes.
6. And Bus-coupler will be closed automatically after 10 seconds after getting
DG2 breaker off status. And total load will be supplied by master DG.
7. If again the total load is greater than 85% rating of single DG, then second dg
will turn on, after getting its VMR healthy signal & Bus-coupler off status, the
DG2 breaker will be closed within 10 seconds.
8. Now again bus-1 gets fed by DG1 and bus-2 gets fed by DG2.
9. When only one DG is running, if there is any fault on that DG, then second DG
will turn on and faulty DG will turn off.
10. When the EB is back or healthy, then two DGs will turn off after 2 minutes,
thereafter 10 seconds EB breaker will gets closed and thereafter 10 seconds
Bus-coupler will be closed, total load fed by EB incomer.

EB DG-1 DG-2 BUS COUPLER

ON OFF OFF ON
OFF ON ON OFF
OFF ON OFF ON
OFF OFF ON ON
Figure 4: Interlock table

Page 6