Manual Sistema Scada
Manual Sistema Scada
Manual Sistema Scada
Client
4500859942 46D
Manufacturer:
461180
Document No. :
461180_Operation Instruction.doc
13,8kV/46kV 60Hz
230V AC, 60Hz; 24 V DC
127/230V AC, 60Hz
Page 1 of 134
Table of Contents:
Table of Contents: ............................................................................................................. 2
Revision History................................................................................................................. 7
1
Principle Front View ................................................................................................ 8
2
Principle Description............................................................................................. 10
2.1
2.2
3
3.1
Switches and Push Buttons ................................................................................................................. 12
3.1.1 Selector Switch Operation Mode GCP/SCADA ............................................................................... 12
3.1.1.1 Purpose ............................................................................................................................................. 12
3.1.1.2 Properties .......................................................................................................................................... 12
3.1.2 Selector Switch Alternator Voltage ................................................................................................... 14
3.1.2.1 Purpose ............................................................................................................................................. 14
3.1.2.2 Properties .......................................................................................................................................... 14
3.1.3 Selector Switch Local Synchronization Manual/OFF/Automatic ...................................................... 15
3.1.3.1 Purpose ............................................................................................................................................. 15
3.1.3.2 Properties .......................................................................................................................................... 15
3.1.4 Control Switch Manual Setting Voltage, Power Factor Lower/0/Higher ........................................... 17
3.1.4.1 Purpose ............................................................................................................................................. 17
3.1.4.2 Properties .......................................................................................................................................... 17
3.1.5 Control Switch Manual Setting Speed, Frequency, Load Lower/0/Higher ....................................... 18
3.1.5.1 Purpose ............................................................................................................................................. 18
3.1.5.2 Properties .......................................................................................................................................... 18
3.1.6 Push Button Red Emergency Stop................................................................................................... 19
3.1.6.1 Purpose ............................................................................................................................................. 19
3.1.6.2 Properties .......................................................................................................................................... 19
3.1.7 Push Button Black Acknowledge/Reset ........................................................................................... 21
3.1.7.1 Purpose ............................................................................................................................................. 21
3.1.7.2 Properties .......................................................................................................................................... 21
3.1.8 Push Button Blue Lamp Test............................................................................................................ 22
3.1.8.1 Purpose ............................................................................................................................................. 22
3.1.8.2 Properties .......................................................................................................................................... 22
3.1.9 Push Button Green Alternator CB ON .............................................................................................. 23
3.1.9.1 Purpose ............................................................................................................................................. 23
3.1.9.2 Properties .......................................................................................................................................... 23
3.1.10 Push Button Red - Alternator CB OFF ................................................................................................ 25
3.1.10.1 Purpose ............................................................................................................................................. 25
3.1.10.2 Properties .......................................................................................................................................... 25
3.2
Indications ........................................................................................................................................... 27
3.2.1 Signaling Column ................................................................................................................................ 27
3.2.1.1 Purpose ............................................................................................................................................. 27
3.2.1.2 Properties .......................................................................................................................................... 27
3.2.2 LED Position Indicator Alternator Circuit Breaker ............................................................................ 29
3.2.2.1 Purpose ............................................................................................................................................. 29
3.2.2.2 Properties .......................................................................................................................................... 29
3.2.3 LED Position Indicator Alternator Earthing Switch ........................................................................... 30
3.2.3.1 Purpose ............................................................................................................................................. 30
3.2.3.2 Properties .......................................................................................................................................... 30
3.2.4 LED Position Indicator Alternator Neutral Earthing Switch .............................................................. 32
461180_Operating Instruction Genset Control Commissioning Edition.doc
Page 2 of 134
4
5
6
4.1
Synchronization of Circuit Breakers .................................................................................................... 47
4.1.1 Synchronization Principles .................................................................................................................. 47
4.1.2 Synchronization Operating Scenarios ................................................................................................. 48
4.1.2.1 Automatic Synchronization from GCP .............................................................................................. 48
4.1.2.2 Manual Synchronization from GCP .................................................................................................. 49
4.1.2.3 Automatic Synchronization from SCADA ......................................................................................... 50
4.1.2.4 Principle Control and Operating Philosophy Alternator Circuit Breaker and Excitation ................... 51
5.1
5.2
5.3
5.4
5.5
5.6
6.1
6.2
6.3
6.4
6.5
Page 3 of 134
Page 4 of 134
7
7.1
LV ENGINE Auxiliaries Panel +EAPx frontview ................................................................................ 114
7.2
Pre lubrication pump 01MJV21AP030-M01 (P007) on MOD006 ...................................................... 115
7.2.1 Start prelubrication ............................................................................................................................ 115
Parameter Start prelubrication ........................................................................................................ 116
7.2.2 Cooling down the engine in case of shutdown .................................................................................. 116
7.2.3 Parameter: Cooling down function .................................................................................................... 116
7.3
Generator heating 01MKA01AH010 (H100) ..................................................................................... 117
7.4
Cylinder Lubrication 01MKA01AH010 (1EM2470) ............................................................................ 118
7.4.1 Area of application ............................................................................................................................. 118
7.4.2 Vgele System .................................................................................................................................. 118
7.4.3 Process sequence: Cylinder lubrication ............................................................................................ 119
Manual operation "Cylinder lubrication ON" ................................................................................... 119
Manual operation "Running-in mode" ............................................................................................. 119
Automatic operation ........................................................................................................................ 119
Control response in the event of failure of the input signals ........................................................... 119
Parameter: Cylinder lubrication ...................................................................................................... 120
7.5
Nozzle cooling water module 01MJG34AC010 (MOD005) ............................................................... 121
7.5.1 Parameters Nozzle cooling water module X0PAB48AC001 (MOD005) ........................................... 121
7.6
Fuel oil module 01END56AP010 (MOD008), HFO / light fuel oil (LFO)-Operation .......................... 122
Diesel operation ............................................................................................................................................. 122
HFO operation ................................................................................................................................................ 122
7.7
HT cooling water preheating module 01MJG31AP020-M01 (P070 on MOD004) ............................ 124
461180_Operating Instruction Genset Control Commissioning Edition.doc
Page 5 of 134
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Panel label
Voltmeter alternator voltage
Ammeter alternator current
Double voltmeter synchronization voltage
Double frequency meter synchronization frequency
Synchronoscope
Selector switch alternator voltage
Multifunctional monitoring unit (MMU)
Automatic synchronization unit
Panel PC
Push button blue lamp test
Push button black acknowledge/reset
Push button red emergency stop
Control switch manual setting voltage, power factor lower/0/higher
Control switch manual setting Speed, frequency, load lower/0/higher
Selector switch local synchronization manual/OFF/automatic
Selector switch operation mode GCP/SCADA
LED position indicator alternator circuit breaker
Push button green alternator CB ON
Push button red alternator CB OFF
Alternator protection device
LED position indicator alternator neutral earthing switch
Signaling column red = engine stopping/standstill
Signaling column yellow = genset alarm
Signaling column green = engine starting/running
LED position indicator alternator earthing switch
Top filter
Filter ventilator
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3.4
Visualization
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OPERATING SCENARIOS
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4.1.1
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Page 54 of 134
OVERVIEW DIAGRAMMS
5.1
Page 55 of 134
5.2
Page 56 of
5.3
Page 57 of 134
5.4
Grid voltage and frequency variation on the busbar shall not exceed normal +/- 5%.
Manual start order for each / of all gen.-sets.
Automatic synchronizing of alternators, mains feeder will synchronize by costumer.
Parallel operation of Power Plant with grid, with adjustable values of active and reactive
Load for each gen.-set.
In the event of grid failure during grid parallel operation, decoupling from the grid within an
extremely short time for safe operation of the power plant.
Page 58 of 134
5.5
This switchboard consists of 2 panels and stands in the engine hall. All the engine sensors are connected to this
switchboard and collected in a control device for sending via Profibus-DP cord to +GCPx and to +EAx panel.
The engine governor are incorporated in this panels and the generator regulator (AVR) is installed.
Page 59 of 134
5.6
This switchboard is delivery part of costumer, stands in the engine hall. All the engine auxiliaries are connected
to this switchboard and collected in a control device for sending via Profibus-DP cord to +GCPx.
Page 60 of 134
6.1
6.2
Page 61 of 134
Page 62 of 134
6.3
6.4
This switch is used for commissioning. In local position is the Start pus button 1HOS1011 at engine
released. By first pressing the engine start preconditions are requested, after the start preconditions are
fulfilled the engine can start, after a second press the engine will start in idle mode.
-
Page 63 of 134
6.5
Generator Synchronisation
The following functions can be preselected using the synchronisation selection switch 232S3:
1- Automatic
0- off
2- Manual
These selections are only available in GCP position. In SCADA position is generally the automatic synchronising
function selected independently of the position of synchronisation selection switch.
Position 0 off
In this position, no synchronisation selection takes place.
Position 1 - Automatic Synchronisation
In this position, the automatic synchronisation device SPM is switched on. The SPM now provides the
synchronism by modifying the engine speed. Once synchronisation is established, the SPM discontinues the
synchronisation command. The generator c.b. is directly closed by this switch on command. If the c.b. closed
successfully, the synchronisation is aborted. The automatic synchronisation can be monitored by the
synchronoscope.
(Adjustment of the SPM see separate description)
The synchronisation time is monitored. If the synchronisation is requested and the selected time has passed,
then this is displayed as fault signal.
Position 2 - Manual Synchronisation
In this position, the synchronoscope is switched on. Now, with the help of the speed adjustment push button, the
generator frequency must be manually adjusted to the bus bar frequency. Rough speed adjustment can be
made by comparing both frequencies (double frequency meter). If both frequencies are about the same, then
one can fine-tune by watching the synchronoscope. If the synchronoscope LEDs are still moving very slowly,
then no more adjustment command should be given. Now the connection can be made by hand.
If the generator c.b. closed successfully, then the synchronisation is aborted.
In order to avoid faulty synchronisation a synchr. check relay integrated in the LED synchronoscope. The green
LED at the top indicates the synchronisation release.
The speed adjustment push button in the +GCP panel is only released during the synchronisation.
The generator voltage is also compared with the mains voltage by the generator regulator. This control is carried
out in order to keep the switch-on peak as low as possible.
CAUTION
1. Please, ensure that before leaving the station, the selector switch for synchronisation is switched back to
Automatic.
6.5.1
Description
Synchronisation monitoring
Dimension
Basic setting
min:sec
02:00
Setting after
taking into
operation
Page 64 of 134
6.5.2
Page 65 of 134
6.6
6.6.1
Basic setting
1
2
Page 1
Nominal value from CCP
Nominal value SCADA
%
%
Indication
100
3
4
%
%
Indication
Indication
5
6
7
8
Dead band
Proportional area Xp
Pulse length
max. pause
%
%
sec
sec
1
30
0,5
2.0
9
10
11
%/s
%/s
%/s
1
1
0,5
12
13
14
15
Unloading value
Del. Load reg. Fault
Release load inc. after change fuel oil
Nominal load (electrical)
%
sec
sec
kW
10
300s
30
8370
16
17
18
19
20
21
%
%
%
%
%
%
%
kw
65
60
75%
70
70
70
97,5
8954
24
25
26
27
28
29
30
31
32
33
34
35
%
C
C
%
s
%
%
%
%
%
%
%
Indication
560
5
1
120
90
Indication
Indication
Indication
100
100
100
36
100
23
see acceptance
certificate
Page 66 of 134
47
48
49
50
51
52
%
s
%
s
s
5
180
30
0
240
53
54
55
56
57
58
59
60
%
s
%
s
s
%
s
s
5
60
30
480
0
3400
30
60
%
%
%
%
100
1
105
1
%
%
102,5
2,5
C
C
%
70
3
2
s
%
5
85
38
39
40
41
42
43
44
45
46
61
62
63
64
65
66
67
68
69
70
71
6.6.2
40
C
%
C
%
C
%
C
%
C
15
100
20
100
21
99,5
30
95,2
40
90,4
to
The load control failure signal arises when the actual value for the set time is beyond the dead zone.
Page 67 of 134
6.7
Loading of Engine
The loading of the engine will be done by curve Shortest possible continus loading (without Jet Assis)
Page 68 of 134
6.8
PCU is a Software-System, which limits the maximum power delivery of the engine dependant on
surrounding conditions:
Load reduction dependant on the ambient air temperature
Load reduction because of unacceptable mechanical overload and speed difference
Load reduction because of too high exhaust gas temperature before turbo charger
The permitted load calculated by the PCU always represents the mechanical load to the engine coupling.
6.8.1
The permitted long-term performance is defined by the compatible limit curve. This curve is established in
the form of support values (table). By fixing up to 5 temperature support values, the limit values for the longterm performance are interpolated each linearly.
The establishing of the actually permissible performance is made in direct dependence of the ambient air
temperature.
Page 69 of 134
6.8.2
Load reduction because of too high exhaust gas temperature before turbine.
In case of excess of a pre-set limit value (e.g. 550C), the permitted load is gradually reduced by steps of 1%
of the nominal load until the temperature limit value is undershot, taking into consideration a steady state
time of 2 minutes. In case the temperature falls lower than 5C (set value), the load can be released again in
1% steps until a limit value is reached after the point 1 or 2 of the permitted load.
REMARKS
All three-load reduction possibilities are always fundamentally calculated through. It is always the
lowest that sets the permitted engine load output.
The load reductions are limited to Pmin (specific to the plant limit value, or default value). As far as an
internal fault in the PCU leads to it, then no maximum permitted load is calculated any more (e.g.
Failure of the ambient temperature sensor), then the higher-ranking load control must reduce the
load of the engine to Pmin on safety grounds.
In order to render load reduction transparent to the client, the following information are visualised on a
display:
Results of the PCU calculation:
Display of the maximum permitted mechanical load because of load monitoring
Display of the maximum permitted load because of exhaust gas temperature
Display of the maximum permitted load because of ambient air temperature
Page 70 of 134
6.9
Page 2
El. Efficiency
Nominal load (mechanical)
Act. Mechanical load
Period monitoring overload
Max. overload per period
Delay overload operation
Remaining time overload
Exh. Gas time load reduction
Hysteresis
Step with load dec/inc
Load inc/dec period exh.
Lower load point (default)
Max. load (overload monit.)
Max. load (exh. Gas temp.)
Max. load (air intake)
Max. permitted load elec.
Derating by speed (normal)
Derating by speed (overload)
Dimension
Basic setting
%
kW
%
min.
min.
sec
min.
C
C
%
min.:sec
%
%
%
%
%
%/%
%/%
97,3
8370
Display
0
20
20sec
Display
555
5
1
120sec
90
Display
Display
Display
Display
1
1
see acceptance
certificate
Page 71 of 134
Fault signal from the monitoring of the exhaust gas temperature behind cylinder.
Max. load of gen. Overtemp.
X-1SZH1004A turbocharger speed max. load red.
X-1SZH1004B turbocharger speed max. load red.
X-1TAHHU001 generator winding overtemp. -A Red.
X-1TAHHV001 generator winding overtemp. -A Red.
X-1TAHHW001 generator winding overtemp. -A Red.
If one of the above named monitoring reacts, then the load is reduced to a pre-settable value (Lower load
point). Only when the corresponding fault signal is quitted, full load operation will be released.
A message Actual engine nominal load exceeded (FE111) is created from the error messages that cause a
reduction in power, see the error message bar or generally if an engine overload exists.
This message serves to warn the operator that the load must be reduced or another machine started as
quickly as possible.
Page 72 of 134
461180_Operating Instruction Genset Control Commissioning Edition.doc
Page 73 of 134
Page 74 of 134
Page 75 of 134
Page 76 of 134
Reset
All generated alarm signals are no longer active if the following conditions are given:
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Page 77 of 134
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Automatic functions:
With charge air temperature control, the fluid flow of LT cooling water via the charge air cooler is controlled.
The reference value for charge air temp. is a linear function of the ambient temperature, measured by the air
intake temperature of the engine.
The controller is released by a load limit high (list of GCP limit values) to prevent condensating in the charge
air cooler.
Manual functions:
In this function the valve can be controlled by push buttons in direction Open and Close
Page 78 of 134
Unit
C
Basic setting
indication
End setting
indication
C
C
%
indication
indication
indication
indication
indication
indication
C
C
85
indication
indication
C
C
C
C
C
C
16
42
28
56
48
42
mbar
mbar
1000
indication
Gain
Integration time
Dead zone
Minimum manipulated variable
Impulse time
Pause time
ms
%
%
ms
ms
3
1m
1
0
1s
5s
sec
%
s
indication
2m40s
indication
200
2
2
Page 79 of 134
CHATCO curve
Example, pls. look MAN requirements for the used engine
The error message X-1TC6180 Chatco c.w. control fault is created, if the control value is recognised as
failed.
Page 80 of 134
6.12.4 Allumatic
Automatic Charge Air Control
AlLumatiC CHARGE AIR TEMPERATURE CONTROL
The requirement of the Allumatic-System is to control the charge air temperature regarding to its dewpoint,
i.e. to keep the charge air temperature as low as possible but still high enough so the air bonded water vapor
will not condensate.
The setpoint of the charge air temperature is the charge air dewpoint temperature before cylinder + 1C
(safety margin).
The lower the charge air temperature the lower is the NOx value and also the fuel oil consumption of an
engine.
The airbonded water vapor reduces the NOx value also.
In case of fault by the Allumatic system, a switch over to CHATCO (charge air control depending of the
ambient air temperature) is necessary.
Operation Modes
The operation modes of the Allumatic are Manual Remote and Automatic Remote
Manual Remote
This mode has to be selected at SCADA by soft touch buttons. With these the operator can move the valve
between the position A-AB (heat exchanger active cooled) and B-AB (heat exchanger bypassed).
Automatic Remote
The software controller is active with LT cooling water pump P025.
Page 81 of 134
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[mbar]
[C]
[C] from CCP
With the result of calculation the charge air temperature can be defined.
- Setpoint for charge air temperature = tdAll dewpoint temperature before Cylinder +1K
Page 82 of 134
Allumatic Mode
The PLC moves the valve to position A-AB in case of temperature value at 2TE6180A is higher than
the dewpoint temperature value before the cylinder +1C
The PLC moves the valve to position B-AB in case of temperature value at 2TE6180A is lower than the
dewpoint value before the cylinder +1C.
CHATCO Mode
The PLC regulates the valve between position A-AB and B-AB regarding to the temperature value at
intake air temperature sensor 1TE6000.
Page 83 of 134
6.12.8 Alarms
In case of emergency stop of the engines, the PLC forces the valve into position B-AB.
Page 84 of 134
Page 85 of 134
6.13 HT cooling water control valve 01MJG31AA010-M01 via TC3180 with MOV 002
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Automatic functions:
The use of this technically advanced control system is necessary as the temperature stabilisation of todays
increasingly complex cooling water systems can no longer be handled with simple means.
This description of HT temperature control applies to cooling water systems which are shown in the PID
diagram from MAN.
With this control system, the cooling water temperature behind the mixing point (in front of the engine with
PT100 sensor) is constantly controlled so that the temperature at the engine outlet (PT100 sensor 3TE3180)
corresponds to the reference value of the engine. The reference value at the mixing point is adapted
depending on the engine load calculated according the turbo charger speed.
The control system basically works in the same way as cascade control with a precalculation of the reference
value via disturbance signals for the internal control circuit (see sketch below).
This temperature controller is released by engine operations.
The inner control circuit controls the HT cooling water temperature in front of the engine and the charge air
cooler (at the mixing point, see value analogue values, (TE3165) HT c.w. temp. bef. P002 to a reference
value which it received from the precalculation of the reference value. This reference value is corrected by
the external control circuit (W1 = Wv + Y2).
The outer control circuit thus controls the HT cooling engine temperature after the engine.
Inner control circuit:
As the inner control circuit measures the temperature at the mixing point, temperature fluctuations are
quickly detected in the inflow (or backflow of the engine) and can be corrected immediately.
Outer control circuit:
The correction value of the outer control circuit is adjusted at regular time intervals (tC) . In detail, this
functions as follows:
After the time tC the correction value Y2 is changed by a fifth of the still existing deviation (Xd2) of the actual
value after engine (X2) of the reference value after engine (W2).
The correction time tC must be set so that is greater than the water circulation time of the system. It may not
be an integral multiple of the value. This is required in order to prevent the control circuit from becoming
unstable. The integration of the controller is thus gradual.
461180_Operating Instruction Genset Control Commissioning Edition.doc
Page 86 of 134
Page 87 of 134
Final setting
90
Calculated value
Actual value
Actual value
Actual setting
Calculated value
Actual value
-2
30
0,3
0
100
500
1,33
120
3
3
15
3
Calculated value
2500
2
4000
5,5
7500
10,5
9500
18
12000
28,5
Actual value
250
1
500
1
Actual value
The error message 1TC3180 HT c.w. control valve fault is created, if a control value is recognised as
failed.
Page 88 of 134
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Page 89 of 134
Unit
C
C
C
%
%
%
C
C
s
Basic setting
indication
indication
indication
26
38
s
%/s
s
%
s
s
s
End setting
32,0
Actual value
Actual value
Actual setpoint
Actual value
Actual value
25,0
50,0
10,0
-1,00
150
20
1
0
1,0
1,0
180
200,0
Page 90 of 134
Remark: In case a slow turn has happened, the user must there and then manually remove the liquid from
the cylinders by turning the engine with the help of the turning gear with opened indicating taps. Blowing
through is not permitted. In case this is not carried out, a slow turn error will happen again automatically
when a new start is attempted. The program tries in every case to successfully end a slow turn procedure.
Values
9-14 bar (according to engine), mechanically
adjustable
2,5U
2s
40s
15s
4h
The forward rotation always strokes the ascending flank of 1SE 1000 on a 1-signal of 5 SE 1000.
In a backward rotation, this would be the descending flank.
For the BACKWARDS rotation direction, this would be the descending flank.
Legend:
X-1SE1000 = revolution count sensor
X-5SE1000 = revolution count sensor for slow turn
Page 91 of 134
Page 92 of 134
6.17.1 General
The control system Splash-Oil temperature monitoring and supervision considered the
crank gear temperatures.
This system measures the temperatures of the splash oil which is collected on the insides
of the individual crankcase covers via collecting channels PT100 sensors. Than the crank
gear temperatures are monitored indirectly.
The supervision function is activated after engine turns higher than a defined speed or if
the mean temperature is over a defined value and remains active until engine standstill.
Page 93 of 134
6.17.2 Subfunctions
The SPLASH OIL temperature monitoring is divided into the following sub functions
In addition to the monitoring of the absolute value, the monitoring of the deviation of each
splash oil sensor from the mean value is also necessary to ensure that an overheating of
one sensor over the entire operating temperature range of the engine is recognized.
- If the measured value in the range of value, no alarm is generated
- Values under the pre alarm delta border the bar graph is green
- If the measured value exceeds the first temperature limit and elapsed a certain time
with 3 seconds, the alarm Pre Alarm Mean is generated
- Values from the pre alarm delta border the bar graph is yellow
- If the measured value exceeds the second temperature limit and elapsed a certain time with 3
seconds, additionally the alarm Alarm Mean Sensor is generated and the request Engine
load reduction is sent (Optional)
- Values from the alarm delta border the bar graph is red
- If the measured value exceeds the third temperature limit and elapsed a certain time
with 3 seconds, additionally to the previous two alarms Over Temperature Alarm
Mean Sensor is generated and the second request Automatic Engine Shutdown is
sent.
- Values from the max delta border the bar graph is red
- If the measured value in the range of values, the alarm is deleted
Page 94 of 134
6.17.6 Not Plausible
The temperature sensor is monitored of sharp signal (Optional). If more than half the
temperature sensors are not plausible, then the request Automatic Engine Shutdown is
sent.
- If the value from temperature sensors jump within in a certain time, the alarm Not
Plausible is generated in the absolute bar graph and in the mean bar graph
- Values from the absolute bar graph are yellow, shows N/A and the value is 0
- Values from the mean bar graph are yellow and shows N/A and the value is 0
- If the value from the temperature sensor is constant and the value is nearly the
mean temp, than the alarm Not Plausible is deleted.
6.17.7 Monitoring active
The monitoring is active, when the engine speed greater than 200rpm and elapsed a
certain time with 16 seconds.
The monitoring is not active, when the engine speed less than 30rpm.
Page 95 of 134
Unit
MVAr
MVAr
Basic setting
12
12
indication
Dead band
Proportional range Xp
Pulse length
Max. pause
MVAr
MVAr
sec
sec
2
5
0.2
5.0
Final setting
MVAr/s
0,85
MW
MVAr
MVAr
MVA
Indication
Indication
12,65
Indication
Indication
Indication
Indication
Indication
Indication
Manual mode:
In this position is the automatic power factor control out of work. The power can now change by selector
switch item 67S5 Voltage decrease or Voltage increase.
Page 96 of 134
Page 97 of 134
Interfaces
For a detailed interface description refer to the DEUFRA manual for the electrical drive of type LE-10.
Power Supply:
Power supply for the valve drive is 24V (DC).
Signals:
OPEN/CLOSED feedback is given as potential free contact.
461180_Operating Instruction Genset Control Commissioning Edition.doc
Page 98 of 134
Malfunction
Malfunction check of charge air blow-off valve (xxMJQ62AA200):
After opening the charge air blow-off valve, the charge air pressure must decrease by 0.1 bar within
10 seconds, compared to the charge air pressure before opening the valve. Otherwise the charge air blowoff valve has a malfunction.
In case of malfunction of the valve an automatic load reduction of the engine shall be carried out and an
error message shall be displayed.
Alarms
The process control system does not create any alarms from the feedback signals of the blow-off valve.
Remote visualisation is only for indication of temperature.
Start requirements
Not applicable for blow-off system.
Page 99 of 134
Description of code
Range:
Value/
Setpoint:
Final
Value:
Input:
xxMJQ61CP900
05.0 mbar
xxMJQ61CT900
-50+400 C
xxMJQ62CG100
on / off
xxMJQ62CG120
on / off
n.a.
n.a.
0 100 %
n.a.
0 100 %
... bar
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
See
Measuring
list
Parameter:
Output:
xxMJQ61CP900
xxMJQ61CP900
xxMJQ61CP900
on / off
on / off
on / off
Please note, for high flexibility and fine-tuning all values shall be adjustable during commissioning. For later
improvements of the control, all operating cycles shall be logged (number of operating cycle, time and main
parameters) in a table for analysis.
KKS-Code
xxMJQ61CT900
xxMJQ61CP900
n.a.
Reference document
DRW 11.81031-0067
DRW 11.81031-0067
n.a.
Interfaces
For a detailed interface description see wiring diagram.
Power Supply:
Power supply for general instrumentation elements is 24V (DC).
Signals:
Analogue signals are provided as 420 mA signal.
Malfunction
No functional protection against malfunction. Wire-break detection is available.
Alarms
The signals are transmitted to the plant control system, where they shall be processed in the following way:
Argument definition
KKS-Code
Range
Value
Action
If
diff. pressure
xxMJQ61CP900
< 0.3 mbar
low
show alarm L
AND
engine load
n.a.
> 60%
If
diff. pressure
xxMJQ61CP900
> 4.0 mbar
high
show alarm H
If
diff. pressure
xxMJQ61CP900
> 4.5 mbar
high high
show alarm HH,
load red. to 60 %
The process control system does not create any alarms from the temperature sensor. Remote visualisation
is only for indication of temperature.
Start requirements
Filters must be in position and good condition. Differential pressure must be below Alarm H.
Selection of master pump shall be possible in two modes activated for AUTO REMOTE:
1. Master pump selection by operator
2. Master pump selection by operating hours
The operator shall select between the two modes.
Location:
Panel PC at CCP (if selector switch at CCP is in CCP-position)
and from SCADA (if selector switch at CCP is in SCADA-position).
Double starter faceplate with two buttons select Operator Master Selection and Master
Selection by Operating Hours. Selected mode shall be indicated.
General:
THE PUMP WHICH IS RUNNING IS THE MASTER PUMP. IT IS NEVER THE STANDBY
PUMP WHICH IS RUNNING ALONE.
A pump which is disturbed cannot be selected as master.
If one or both pumps are disturbed no selection of mode for master selection or
master is possible.
Operating hours criteria:
Operating hours as the criteria for master shall only be considered for the next AUTO
start of the pumps, not during running pumps.
If pumps are in REMOTE MANUAL, the operator can between selection by operator or
by operating hours if pumps are running or standstill. The operator can change the
master only if both pumps are running or standstill.
Default by PLC Start: Pump 1 is master, master pump selection by operator.
Each selection causes an event.
Description:
Scenario 1:
Pumps standstill and in REMOTE AUTO.
Operator selects Master pump selection by operator (if not already selected)
Operator selects pump 1 as master. If automatic request start of one pump, pump 1 will start.
461180_Operating Instruction Genset Control Commissioning Edition.doc
or
Operator selects pump 2 as master. If automatic request start of one pump, pump 2 will start.
Scenario 2:
Pumps standstill and in REMOTE AUTO.
Operator selects Master pump selection by operating hours (if not already selected)
Pump 1 has less operating hours than pump 2. If automatic request start of one pump, pump
1 will start.
Pump 2 has less operating hours than pump 1. If automatic request start of one pump, pump
2 will start.
or
or
or
or
or
or
Scenario 6:
Pumps standstill and in REMOTE MANUAL or in LOCAL MANUAL
Selection of the master selection mode and the master pump shall be possible, but has no
influence in REMOTE MANUAL.
Operator starts pump 1. Pump 1 becomes or stays master.
Operator starts pump 2. Pump 2 becomes or stays master.
Scenario 7:
Pumps standstill and in REMOTE MANUAL or in LOCAL MANUAL
Operator starts pump 1. Pump 1 becomes or stays master.
Pump 1 failure and stop, master changes to pump 2 but no start of pump 2 (no AUTO)
Operator starts pump 2. Pump 2 becomes or stays master.
Pump 2 failure and stop, master changes to pump 1 but no start of pump 1 (no AUTO)
Operator starts pump 1 and 2. The first started pump becomes or stays master.
Master selection mode is not effected.
Scenario 8:
Pump 1 is running in REMOTE AUTO.
Operator selects MANUAL REMOTE and starts pump 2 and stops pump 1.
Pump 2 becomes master.
Pump 2 is running in REMOTE AUTO.
Operator selects MANUAL REMOTE and starts pump 1 and stops pump 2.
Pump 1 becomes master.
Master selection mode is not effected.
or
Scenario 9:
Pump 1 is running in REMOTE MANUAL.
Operator selects REMOTE AUTO
Pump 1 keeps master independent from master selection mode (no changeover to lower
operating hours).
Pump 2 is running in REMOTE MANUAL.
Operator selects REMOTE AUTO
Pump 2 keeps master independent from master selection mode (no changeover to lower
operating hours).
These panels contain the power components for the motor auxiliaries and the data interface to the
appropriate ECPx panel and stands in the mechanical annex.
7.1
7.2
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
If the motor protective switch is triggered, the oil pump is switched off by the software and hardware. This
switching-off is shown as an error message on the display.
The oil pump has two functions:
1. Start prelubrication
2. Cooling down the engine in case of shut down
The following positions 1-2 are described in the selection switch AUTOMATIC Remote position!
7.2.1
Start prelubrication
Start prelubrication is used to supply the engine with lubricating oil before it is started in order to keep the
mechanical loading of the engine as low as possible Start prelubrication is switched on in the start-up
preconditions. (Start-up preconditions means that the corresponding auxiliary drives for a module start are
activated). A set prelubrication time then follows. After the specified prelubrication time has elapsed and the
system has built up the required prelubrication pressure, the start signal is issued.
Start prelubrication is not necessary, if the standstill time is less than the adjustable time (Max. standstill
time start prelubrication is required).
General:
If an emergency stop is activated or a pump fault, then the pump is switched off by software and hardware.
Start prelubrication
Max.
standstill
time
start
prelubrication is required
X-1PSH2170 lube oil press.
release Start engine
Hysteresis
Dimension
Basic setting
sec
sec
60
1800
bar
0.3
bar
0.1
see acceptance
certificate
Caution: If the selection switch is in the "OFF" position, prelubrication cannot be carried out, and no start
command is issued.
7.2.2
In case of shutdown of the engine the oilpump will start for an adjustable time to remove the heat from the
engine.
General:
If an emergency stop is activated or a pump fault, then the pump is switched off by software and hardware.
7.2.3
Dimension
Basic setting
600
see acceptance
certificate
7.3
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Automatic function:
The generator heating is released, when the engine is not running
Manaul remote function:
In this position the heating is manual controlled by software push buttons on / off.
General:
If an emergency stop is activated, then the heating is switched off by software.
7.4
MANUAL REMOTE
MANUAL LOCAL
7.4.1
AUTOMATIC LOCAL
AUTOMATIC REMOTE
Area of application
To improve the running characteristics, lubricating oil is added to the individual pistons via special boreholes
in the cylinder sleeve.
7.4.2
Vgele System
In the Vgele system, a pump is used to suck lubricating oil from the pressurised engine oil line and feed it to
a block distributor. Through cyclical switching of different oil lines, the block distributor supplies all cylinders.
In Vtype engines, each cylinder bank has a separate system for cylinder lubrication, and both cylinder
lubrication systems are controlled in the same way. One outlet of the block distributor is equipped with a X1FE2470A/B proximity switch that checks the correct functioning (circulation of the block distributor). The
system is considered to be functioning correctly if the signal of the proximity switch changes its switching
status 1FAL2470A/B at least once in the time KSH0010.
The electric motor for cylinder lubrication is protected by a a motor protective switch. If the MCB trips, the
engine control unit receives an overload signal and cylinder lubrication is deactivated, in V-type engines both
the A and B sides are switched off.
There are three possible operating modes:
Manual operation: "Cylinder lubrication ON, for activating cylinder lubrication if the engine stops, for
example to enable lubrication when turning the engine.
Manual operation: "Running in mode, for activation of cylinder lubrication when starting the engine,
for example to start the engine after repair work.
Automatic operation, standard mode, which activates cylinder lubrication from an engine load greater
than X-2GT1022.
The status of cylinder lubrication can be called in the display.
7.4.3
The function can be executed by the operator while the engine is stationary during maintenance work. This
function is automatically deactivated once the time KSH0300 has elapsed. The "Cylinder lubrication ON"
operating mode is not available when the engine is running.
If the function is activated again while it is already running, the time set in KSH0300 is reset and starts again
from the beginning.
If the engine is started while the function is active, the system switches to automatic mode (see section
7.14.6).
This function is used to ensure gentle running in of new components following repair, through permanent
lubrication. This function has no time limit and is reset by manually switching off. The "Run-in mode
operating mode can be selected when the engine is stationary and while it is running, but the control unit
does not activate lubrication until the engine is running.
Automatic operation
Automatic operation is the standard operating mode. This mode is always active if neither of the modes
"Cylinder lubrication ON" (only if the engine is running) or "Run-in mode is selected.
In automatic operation, cylinder lubrication is switched on as soon as the engine is running and the load
switching point X-8GSH1022 is exceeded. To prevent constant switching on and off if the engine is running
close to the load switching point, the system takes a hysteresis an delay (KSH0020) into account when
switching off lubrication.
If the lubrication oil pressure signal fails, cylinder lubrication is not activated.
If the engine speed fails, manual operation "Run-in mode and automatic operation are not activated or
deactivated.
The manual operating mode "Cylinder lubrication ON is not affected by a fall in engine speed or an absence
of the engine speed signal.
If the load signal fails, cylinder lubrication is activated when the engine speed X-1SSH1000 is exceeded.
The manual operating modes are not affected by a failure of the load signal.
The parameters used in the description above (pressures, time monitoring) are shown here as examples:
Parameters
Sample values
10 s
20 s
300 s
50 %
5%
200 U/min
20 U/min
1 bar
7.5
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
7.5.1
Unit
m :s
Set value:
7.6
Fuel oil module 01END56AP010 (MOD008), HFO / light fuel oil (LFO)-Operation
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
Preselection of the operating mode is made by means of a panel PC situated pushbutton or can be
preselected from SCADA.
On every fuel switchover an appropriate message is issued to point out the actions to be performed on the
fuel system by the operators staff (open and close cooling/heating valves on the fuel module). In addition,
the load is reduced to approx. 70% for approx. 10 minutes to prevent full-load operation with mixed fuel. The
parameters named above can be set.
Diesel operation
The diesel operating mode is used for start-up and as a backup procedure if the HFO conditions are not met.
If the fuel module is switched over to diesel operation from HFO operation, fuel excessive temperature
monitoring (TAH5070) is activated delayed.
If the alarm fuel excessive temperature TAH5070 is displayed for longer than a set time, the genset is shut
down.
HFO operation
Criteria for HFO switch off heavy fuel oil (HFO) operation
Viscosity, if the error message Viscosity high is issued, HFO operation is locked.
By selection of light fuel oil (LFO) operation
If the genset cannot be operated with HFO on account of the criteria mentioned above, the fuel module is
switched over to diesel operation immediately.
The following criteria must be met in order to be able to switch over from diesel oil operation to HFO
operation:
The locking criteria (see above) may not be present.
The HT cooling water temperature must exceed a set value.
The generator circuit breaker must be switched on and the genset must be operated at least with a set
min rating.
Temperature HFO in 3T022
7.7
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
7.8
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
7.9
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
xxMJV21BB010 =T001
The lubrication oil valve is used to supply fresh oil to the engine.
The levels limits LSH T001 (max.) and LSL T001 (min.), 1LAL T001 (max.max) and 1LAL T001 (min.min)are
formed by the sensor 2PTT001 ore from 1PTT001.
The exceed of the limit value 1LALT001 (min.min) will cause the fault signal lub.oil level low.
The exceed of the limit value 1LALT001 (max.max) will cause the fault signal lub.oil level high, depending of
status of engine.
Operating elements by Software:
Control functions:
Closed
Automatic
Open
Position Automatic operation:
In this position automatic control is carried out, when the filling level 2LSL T001 (min.) is reached, the valve
is opened when the filling level 2LSH T001 (max) is reached the valve is closed. A request is given to the
lubricating oil refill pumps (P012), by opennig signal of valve SOV 2303.
Position Manual operation:
In this position manual control is carried out, by order from software push buttons open / close. A request is
given to the lubricating oil refill pumps (P012), by opennig signal of valve SOV 2303.
7.9.1
T001=xxMJV21BBQ10
Status:
Page : Limit values
Description of measuring point
1LAL T001 (min.min)
Hysteresis
1LAH T001 (max.max.) operation
Hysteresis
1LAH T001 (max.max.) stand still
Hysteresis
2LSL T001 (min.)
Hysteresis
2LSH T001 (max.)
Hysteresis
Unit
mbar
mbar
mbar
mbar
mbar
mbar
mbar
mbar
mbar
mbar
Set value:
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC LOCAL
AUTOMATIC REMOTE
fans
tdelay start engine
Engine
Engine
fans
xxUMF15AN011/013
If
Then
Then
Then
Then
Then
Then
Fans
01UMF15AN011/013
Air louvers
01UMF15AA200/210
Air louver limit switches 01UMF15CG100/160
xxMJA10AG010
xxMJA10AG010
xxUMF15AN011/013
xxMJA10AG010
xxMJA10AG010
xxUMF15AN011/013
range
value
action
Yes/No
Yes/No
Open/Closed
Open/Closed
available
available
Yes
Yes
To open
Open
On/Off
0...30min
On (stage 1)
5min
Release start requirement
Start
On (stage 2)
Start/Stop
On/Off
Start/Stop
On/Off
0...30min
15min
On/Off
Open/Closed
Open/Closed
Stop
On (stage 1)
Start
Off
To closed
Closed
With regard to a high availability there shall be also the possibility to receive release start requirement and
operate the engine for short terms if only one of the twin ventilation towers of the engine has the full
functionality for the correct operation. But this operation option should be only used in exceptional cases and
a prompt maintenance of the damaged ventilation unit is necessary. MAN Diesel & Turbo SE does not
recommend engine ventilating with only one ventilation unit and assumes no responsibility if the operator use
this option for continuous operation.
In case of two damaged ventilation units the related engine must not be in operation /must be stopped.
Please pay attention:
- in case of switching down from full speed (stage 2) to low speed (stage 1), a delay of ten (10) seconds
will be needed in order to enable the fan adequately slow down prior to connecting it to lower speed
- in case of switching up from low speed (stage 1) to full speed (stage 2) no delay is needed
7.10.4 Malfunctions
Start conditions:
Argument definition
If
Air louvers
Then
Delay
If
Air louvers
limit switch
Then
Alarm
If
If
Then
Then
Air louvers
Delay
Air louvers l
limit switch
Alarm
Related fan of
faulty air louver
KKS
01UMF15AA200/210
01UMF15CG100/160
range
Open/Closed
0-5 min
Open/Closed
value
2 min
Action
To closed
Start
Not closed (S2 signal)
Initiated in control
system
01UMF15AA200/210
01UMF15CG100/180
Open/Closed
0-5 min
Open/Closed
2 min
To open
Start
Not Open (S3 signal)
Initiated in control
system
01UMF15AN011
or
01UMF15AN013
Blocked/Released
KKS
01UMF15CG100/160
or
01UMF15CG120/180
range
Open/Closed
Blocked
During operation
Argument definition
If
Air louvers
limit switch
Then
Alarm
And
Related fan of
faulty air louver
01UMF15AN011
or
01UMF15AN013
value
Action
Not open
Initiated in control
system
Off
On/Off
With regard to a high availability there shall be the possibility to operate the engine for short terms if only one
of the twin ventilation towers of the engine has the full functionality for the correct operation. But this
operation option should be only used in exceptional cases and a prompt maintenance of the damaged
ventilation unit is necessary. MAN Diesel & Turbo SE does not recommend engine ventilating with only one
ventilation unit and assumes no responsibility if the operator use this option for continuous operation and
ignore maintenance.
In case of faulty air louvers on both ventilation units the related engine must not be in operation /must be
stopped.
Failure on electrical motors
Argument definition
If
fans
And
If
Then
Fuse of motor
(stage 1)
Concerned
motor
Argument definition
If
fans
KKS
01UMF15AN011
and
01UMF15AN013
01UMF15AN011 M01
or
01UMF15AN013 M01
01UMF15AN011 M01
or
01UMF15AN013 M01
KKS
01UMF15AN011
range
On/Off
value
Action
On (stage 1)
Has tripped
Stage 1 / stage 2
range
On/Off
Switch in stage 2
value
Action
On (stage 2)
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Then
Fuse of motor
(stage 2)
Concerned
motor
01UMF15AN011 M01
or
01UMF15AN013 M01
01UMF15AN011 M01
or
01UMF15AN013 M01
Has tripped
Stage 1 / stage 2
Switch in stage 1
In case of overheated bearings from electrical motors of the fans (01UMF15AN011/013) the EAP will receive
a signal. Following the EAP will stop the concerned electrical motor automatically.
7.10.5 Alarms
In case of high contamination of the air filters a differential pressure high alarm will be initiated. For this the
powerhouse inlet ventilation units are equipped with differential pressure transmitter.
If
Argument definition
Pressure switches
Then
Pre-Alarm
If
Pressure
Then
Alarm
KKS
01UMF15CP100
or
01UMF15CP200
range
50...500 Pa
value
250
Pa
Action
Above
Initiated in control
system
01UMF15CP101
or
01UMF15CP201
50...500 Pa
Above
300
Pa
Initiated in control
system
In case of pre-alarm due to high contamination the filter should be changed in the next time (time before the
other differential switch gives alarm). During the filter change procedure ensure that the associated inlet
ventilation unit is not running.
In case of alarm due to high contamination the filter should be changed as soon as possible. With differential
pressures of more than 300 Pa there is no guarantee to get the full required volume flow. During the filter
change procedure ensure that the associated inlet ventilation unit is not running.
In case of an alarm of the fire detection system, the inlet ventilation units have to shut down their
ventilation automatically.
Argument definition
If
Fire alarm
Then Fans
KKS-Code
range
01UMF15AN011/013
Start/Stop
value
action
To stop
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE
AUTOMATIC LOCAL
MANUAL REMOTE
MANUAL LOCAL
AUTOMATIC REMOTE