Technical Proposal

RIVTAF Golf Estate Generator

Synchronization Project
Date: Monday 17th April 2023

Document: Technical Report on RIVTAF Golf Estate Generator Synchronization Project

Author(s): Efe Ighorodje / Danny Echo

TABLE OF CONTENTS

1.0 ABBREVIATIONS…………………………………………………………………………………….3

2.0 LIST OF FIGURES…………………………………………………………………………………….4

3.0 INTRODUCTION……………………………………………………………………………………...5

3.1 DOCUMENT PURPOSE……………………………………………………………………...5

3.2 PROPOSED PROJECT SUMMARY…………………………………………………………5

3.3 WORK SCOPE DEFINITION………………………………………………………………...6

4.0 CONTROL SYSTEM PROPOSED DESIGN…………………………………………………………7

4.1 SINGLE LINE DIAGRAM……………………………………………………………………7

4.2 PROPOSED CONTROL SYSTEM ARCHITECTURE……………………………………...8

4.2.1 POWER MANAGEMENT SYSTEM……………………………………………9

4.2.2 FUNCTIONS OF POWER MANAGEMENT SYSTEM………………………..9

4.2.3 GENERATOR CONTROL UNIT (GCU)………………………………………10

4.2.4 FUNCTIONS OF GENERATOR CONTROL UNIT…………………………..10

4.2.5 AUTOMATIC TRANSFER SYSTEM…………………………………………11

4.2.6 FUNCTIONS OF THE AUTOMATIC TRANSFER SYSTEM………………..11

4.2.7 AIR CIRCUIT BREAKER (ACB) SYSTEM…………………………………..11

4.2.8 FUNCTIONS OF THE AIR CIRCUIT BREAKER SYSTEM…………………11

4.3 PROPOSED PANEL ARRANGEMENT……………………………………………………12

4.4 FUNCTIONAL DESCRIPTION OF THE PROPOSED CONTROL SYSTEM……………13

4.4.1 OPERATION SCENERIOS…………………………………………………….13

4.4.2 OPERATING MODES………………………………………………………….13

5.0 INTEGRITY CHECK ON TRANSFORMER UNIT………………………………………………...15

6.0 INTEGRITY CHECK ON GENERATOR UNIT…………………………………………………….15

7.0 OUTDOOR CABLE INSTALLATION & EARTHING……………………………………………..15

APPENDIX: RIVTAF GOLF ESTATE GENERATOR SYNCHRONIZATION TIME SCHEDULE

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1.0 ABBREVIATIONS

AC Alternating Current

ACB Air Circuit Breaker

ATS Automatic Transfer Switch/System

AVR Automatic Voltage Regulator

BDV Breakdown Voltage

GCU Generator Control Unit (also referred to as Generator Control System in this
document)

HMI Human Machine Interface

IEC International Electrotechnical Commission

MCB Miniature Circuit Breaker

PHCN Power Holding Company of Nigeria

PI Polarization Index

PLC Programmable Logic Controller

PMS Power Management System

RMU Ring Main Unit

UPS Uninterrupted Power Supply

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2.0 LIST OF FIGURES

Figure 1: Block diagram showing the existing Power system architecture at RIVTAF Golf Estate

Figure 2: Block diagram showing the proposed Power system architecture at RIVTAF Golf Estate

Figure 3: Single Line Diagram for Modified Power System Network at Rivtaf Golf Estate

Figure 4: Control system Architecture for proposed power system

Figure 5: Proposed Panel Arrangement showing the various components

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3.0 INTRODUCTION
3.1 DOCUMENT PURPOSE:
This document gives a technical description of a proposed generator synchronization system for Rivtaf Golf
Estate, Port-Harcourt, Rivers state.
This document will be used as a reference for the detailed hardware and software design.

3.2 PROPOSED PROJECT SUMMARY:

The RIVTAF Golf Estate Generator synchronization project will contain six (6) JMG generator units
comprising 4 Nos. of 700kVA and 2Nos. of 500kVA rated generators. All six (6) generator sets will be
mounted on a concrete platform in a designated area.
A switchgear will be located in an existing switchboard room. This switchgear will contain one (1) no. of
Power Management System (PMS) panel, six (6) nos. of Generator control Units, six (6) nos. of 400VAC
Air Circuit Breaker panels and one (1) No of distribution panel.
The Generator Control Units together with the Power Management System will form the Control System
for the Generator sets and the 400VAC Air Circuit Breakers.
Figure 1 shows a block diagram of the current Power system arrangement at RIVTAF Golf Estate. Figure
2 displays a block diagram of the proposed Power system arrangement containing the generator
synchronization system

Figure 1: Block diagram showing the existing Power system architecture at RIVTAF Golf Estate

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Figure 2: Block diagram showing the proposed Power system architecture at RIVTAF Golf Estate

(Each of the substations is equipped with RMUs, step-down transformers, change-over units and distribution boards)

3.3 WORK SCOPE DEFINITION:

1. Design and construction of control system with the following capabilities:

i. Multiple generator synchronization
ii. Load sharing
iii. Load dependent Start/Stop (LDSS)
iv. Automatic Transfer System (between PHCN and Generator)
v. Manual and automatic operation capability
2. Integrity check on the existing 2.5MVA rated 0.415/11kV step-up transformer.
3. Integrity check on the AVR, speed governor and generator engine for all existing generator units
4. Load test to be carried out on all 6 generator units to determine the voltage and frequency droop.
5. Supply of Uninterrupted Power Supply (UPS) unit for Control system
6. Supply of 2 Nos. of 700kVA rated JMG generator units.
7. Supply and installation of interconnecting power and control cables between the generator units
and the synchronization panel.
8. Supply and installation of interconnecting power cables between the synchronization panel and the
2.5MVA step-up transformer.
9. Transportation of synchronization panel to site
10. Installation, testing and commissioning of control system
11. Reliability test and system hand-over to client.

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 4.0 CONTROL SYSTEM PROPOSED DESIGN

4.1 SINGLE LINE DIAGRAM

Figure 4 below shows a single line diagram of the electrical network after introducing the proposed
synchronization system to the existing power system in the estate.

Figure 3: Single Line Diagram for Modified Power System Network at RIVTAF Golf Estate

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 4.2 PROPOSED CONTROL SYSTEM ARCHITECTURE:

The control system consists of the following components:

1. A Power Management System (PMS), for the overall control of the six (6) generator sets and the
power transfer system.
2. The Generator Control Unit (GCU) for each generator set, controlling the engine, generator and
auxiliary equipment.
3. The Automatic Transfer System (ATS) for automatic power transfer between PHCN supply and
stepped-up synchronized generator supply.
4. The control system, consisting the GCUs, PMS and ATS, is supplied by a 230V UPS

2.2.1

Figure 4: Control system Architecture for proposed power system

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4.2.1 POWER MANAGEMENT SYSTEM
The following main components will be mounted on the Power Management System Panel
1. Siemens Simatic CPU 315 PLC
2. Siemens 15-inch Touch screen HMI, mounted on the cabinet door.
3. Power Supply units
4. Panel light with socket outlet, mounted on the panel door
5. Miniature Circuit breakers with auxiliary contacts for power distribution and protection
6. Emergency button for emergency system shutdown. (Also mounted on the panel door)
7. Light indicator will be mounted on the panel to indicate the availability of UPS power.

4.2.2 FUNCTIONS OF POWER MANAGEMENT SYSTEM

1. VISUALIZATION & REAL TIME MONITORING:
The Power Management system is the central control unit of the entire synchronization system. It
will be designed to communicate efficiently with other sections of the system by using the IEC
61784 communication protocol (PROFIBUS). Vital information such as the parameters of the
generated power, breaker statuses, diagnostic alarms and so on will be sufficiently available to the
end user through a user-friendly and easy-to-understand graphic interface.

Below is the list of information that will be made available for visualization:

a. Single line display of the generators and the 11 kV switchgear.

b. Measurements and statuses for each of the generator sets, such as;
i. Generator Voltage
ii. Generator Current
iii. Generator Circuit Breaker status
iv. Real and Apparent Power generated
v. Power factor
c. Total active and apparent Power consumed
d. 11kV PHCN and generator breaker statuses
e. Active Alarms and Alarm history

2. SYSTEM SAFETY:
In the case of an emergency, ease in system isolation is vital. The Power Management system
provides such function. All generator breakers will be opened and generator units will be shutdown
in cases of emergency

3. AUXILIARY POWER DISTRIBUTION:

The PMS is also responsible for distribution of 24VDC and 230VAC power to other sections of the
synchronization system. It also monitors the status of the Miniature Circuit Breakers (MCB) that
are used in the distribution. End-user will be prompted in the case of any interruption.

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 4. REMOTE START COMMAND TO GCU:
The PMS will be responsible for providing remote start command to the Generator control Units.
With this command, the GCUs can automatically start the generators, synchronize and share loads.

5. DATA LOGGING:
The proposed PMS makes it possible for incorporating of technologies for capturing and storing of
data that can be analyzed and can help for future planning of power generation and distribution in
the estate.

4.2.3 GENERATOR CONTROL UNIT (GCU):

The GCU constitutes the second control hierarchy after the Power management system. The following main
components will be mounted on the Generator Control Panels;
1. Deep Sea Electronics Load Sharing and Synchronizing Control Module (DSE8610) (Mounted on
the cabinet door)
2. Industrial PROFIBUS to CAN converter
3. Auxiliary relays (interfacing contacts)
4. Miniature Circuit Breaker for protection
5. Panel light

4.2.4 FUNCTIONS OF GENERATOR CONTROL UNIT:

Below is a list of its functions:
1. Manual/Automatic selection
2. Manual Start Generator set
3. Manual Stop Generator set
4. Manual/Automatic Open of Generator Circuit Breaker
5. Manual/Automatic Close of Generator Circuit Breaker
6. Automatic Multiple Generator sets synchronization
7. Automatic real and reactive Load sharing
8. Load Dependent Start/Stop of Generator sets
9. Monitoring of Generated Power parameters (such as Voltage, frequency, power factor, etc.)
10. Generator selection and sorting

A brief explanation on the tenth (10th) function. The system will be designed with Load dependent
Start/Stop capabilities. This means that not all generators will be running at the same time over a long
period of time except the load demands it. The proposed Generator Control Unit will be designed such that
generators can be arranged in order of priority based on their availability. For example, a generator unit that
is 90% fit for operation can be given higher operational preference by the system while a generator that
requires maintenance will be given a lower preference.

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4.2.5 AUTOMATIC TRANSFER SYSTEM:
The Automatic Transfer system constitutes the third (3rd) hierarchy after the Generator Control System. The
main components that will be mounted on the ATS panel are:
1. Deep Sea Electronics Auto Transfer Switch & Mains (Utility) Control Module (DSE8660)
(Mounted on the cabinet door)
2. Sentron PAC3200 Power Meter.
3. Light indicators for availability of 3-phase power (Red, Yellow, Blue).
4. Panel light
5. Miniature Circuit Breakers for protection.
6. Bus bar terminals for connection of power cables to 0.415/11 kV step-up transformer.

4.2.6 FUNCTIONS OF THE AUTOMATIC TRANSFER SYSTEM:

Below is a list of the functions of the proposed ATS;
1. Monitoring of availability of power from utility to ensure generator power is supplied at the exact
time required
2. Mains (Utility) failure detection
3. Automatic/Manual Close of breaker for 11kV incoming supply from Mains/Utility/PHCN
4. Automatic/Manual Open of breaker for 11kV incoming supply from synchronized Generators
output.
5. Synchronized Generator power monitoring.

4.2.7 AIR CIRCUIT BREAKER (ACB) SYSTEM:

The main components that will be mounted on the Air Circuit Breaker panels are listed below:
1. 1250Amps rated Air Circuit Breaker. (Schneider EasyPact MVS12N4NW6A)
2. Sentron PAC3200 Power Meter.
3. Light indicators showing the state of the circuit breakers
4. Emergency switch for each generator unit.
5. Miniature Circuit Breakers for protection

4.2.8 FUNCTIONS OF THE AIR CIRCUIT BREAKER SYSTEM:

The functions of the system are enumerated below;
1. Power system protection such as Overload, Short-time, Long and Instantaneous fault protections
through the Electronic Trip unit (comes along with the Air Circuit Breaker).
2. Monitoring of Air circuit Breaker states such as Closed, Opened, Healthy and tripped through the
light indictors
3. Safety shutdown of individual generator sets without impeding operation.
4. Transmitting of information about power from each generator set to the Power Management System.

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 4.3 PROPOSED PANEL ARRANGEMENT
Below is the panel arrangement for the proposed synchronization system;

LEGEND

Figure 5: Proposed Panel Arrangement showing the various components

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4.4 FUNCTIONAL DESCRIPTION OF THE PROPOSED CONTROL SYSTEM
This chapter provides a functional description of the synchronization system
4.4.1 OPERATION SCENERIOS
1. SCENERIO 1:
In the case of a Mains (Utility) failure, the 11kV mains incoming breaker will be opened and the generator
incoming breaker to 11kV busbar is closed by the Automatic Transfer System. Remote start command from
the PMS will be sent to the GCUs. The GCUs will in-turn start the generator sets. They will be started in a
sequence that is based on the priority that has been set on the GCUs by the end user.

All available generator units will be started, synchronized sequentially in the order of their priorities and
the load that is demanded will be shared accordingly. At least five out of the six generators should be
available at any given time. This is to ensure that the generated power meets the estimated peak electrical
load of 2MW that is consumed by the estate. If after all the generator have been synchronized, the load
demand is less than the 2MVA, the Generator Control system will reduce the generated power to match the
demanded power by stopping generating sets (starting from the least in the priority list).
The Generator Control System will add or drop generating units to the network based on increase or
decrease in the load demanded.

2. SCENERIO 2:
When Mains is restored, the Automatic Transfer System (ATS) ensures a safe and open transition from
generator supply to Mains supply by closing opening the 11kV generator incoming breaker and closing the
11kV Mains incoming breaker
After the transition to Mains, the Generator Control Units automatically open the Air Circuit breakers and
shuts down the generating units.

4.4.2 OPERATING MODES

Based on the proposed design, the system can be operated in 2 modes:
1. Automatic Mode
2. Manual Mode

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 1. AUTOMATIC MODE:

Automatic Mode can be selected by pressing the button on the DSE8610 modules that are mounted
on the GCU panels and the DSE 8610 module that is mounted on the ATS panel. In this mode, the following
actions are carried out;
1. Automatic Transition of Power supply from Mains to Generator and Vis versa when Mains is
present and absent respectively.
2. Automatic synchronization of generators
3. Automatic Load-sharing of load demand among synchronized generators
4. Automatic starting and stopping of generator sets based on load demand
5. Safe shutdown of system during emergency.

2. MANUAL MODE

Manual Mode can be selected by pressing the button on the DSE8610 modules that are mounted on
the GCU panels and the DSE 8610 module that is mounted on the ATS panel. In this mode, the following
actions can be carried out;
1. Manual starting and stopping of generator sets
2. Manual closing and opening of Air Circuit Breakers
3. Manual closing and opening of 11kV rated incoming breakers from Mains and generator.
4. Safe shutdown of system during emergency.
The manual operation of the system should only be used for test purposes during maintenance.

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5.0 INTEGRITY CHECK ON TRANSFORMER UNIT
In order to verify the integrity of the 2.5MVA rated 0.4/11kV step-up transformer (that is responsible for
stepping up the synchronized generator power for supply to the substations that are installed in various
locations of the estate), The following checks will be carried out:
1. Functional tests/checks on Pressure release Valves & Buchholz relay systems
2. Insulation Resistance and Continuity tests on Transformer windings.
3. Polarization index (PI) test on the Transformers
4. Earth resistance tests in all the Earth pits at the Transformer yard.
5. Cleaning and greasing of all the Earth pits at the Transformer yard.
6. Insulation Resistance and continuity tests the Primary and Secondary cables of the Transformers.
7. Prove all associated all controls/ Inter Trip signals between Transformers & Switch board.
8. BDV tests on Transformer oils, if result is lower than minimum expected value, Oil
Regeneration/Filtration would be recommended.
9. Energization of transformers and monitor parameters

6.0 INTEGRITY CHECK ON GENERATOR UNIT

The following checks will be carried out on the existing generator sets to verify the integrity of the units:

1. Site inspection to ensure that installations are rightly done.

2. Inspection on power and control circuit cabling to confirm it is rightly done.
3. For indirect coupling of Engine and alternator, carry out alignment checks. (Optional)
4. Use electronic service tools to access engine ECM/EIS and confirm all programmable parameters.
5. Load test (kW and kVAr) to determine voltage and frequency droop of each generating test.
6. Short/Open circuit and Earth Leakage test.
7. Carry out mechanical checks on Generator, fill radiator, oil etc
8. Run Generator on stand-alone and confirm all parameters are okay.
9. Phase sequence test on the switch board to be sure phase rotation as per designed.

7.0 OUTDOOR CABLE INSTALLATION & EARTHING

1. Carry out IR & continuity tests on all cables before & after cable installation.
2. Excavate cable trench as per project drawings (standard specs: 1.0m for HV cables & 0.6m for
LV cables.)
3. Prior to cable installation, ensure the trenches are debris free.
4. Carry out cable installation between & back fill up to 300mm using sharp sand. Install cable slabs
& backfill completely.
5. Carry out cable termination & hook-up using appropriate cable glands & lugs.
6. Cable Risers, Ladders & Trays would be used as points of hook-up & termination, if need arises.

Carry out integrity tests & checks on existing Earthing installations, if result is less than 1ohm, Earthing
improvement would be recommended. All new Earthing installations would be bonded or tied to the
existing Earthing

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ea
te RIVTAF GOLF ESTATE GENERATOR SYNCHRONIZATION PROJECT TIME SCHEDULE
Company:
Enter Crown
Company Name in cellAutomation
B2.
Enter the name of the Project Lead in cell B3. Enter the Project Start date in cell E3. Pooject Start: label is in cell C3.
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MONTH 1 MONTH 2 MONTH 3 MONTH 4 MONTH 5
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TASK DESCRIPTION PROGRESS START END WK 1 WK 2 WK 3 WK 4 WK 5 WK 6 WK 7 WK 8 WK 9 WK 10 WK 11 WK 12 WK 13 WK 14 WK 15 WK 16 WK 17 WK 18 WK 19 WK 20
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Phase 1: PLANNING AND DESIGN OF SYNCHRONIZATION SYSTEM
Do not delete this row. This row is hidden to preserve a formula that is used to highlight the curren day within the project schedule.
Task 1 Conceptualizing and design of synchronization system 100%
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B Phase 2 : PROCUREMENT & ACQUISITION
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B Task 1Procurement of Components for Panel building 0% WK 1 WK 4
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w Task 2Procurement and delivery to site of 2 Nos. of 700kVA rated Generators 0% WK 1 WK 4
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ce Phase 3 : BUILDING, TRANSPORTATION & INSTALLATION OF SYNCHRONIZATION PANEL
Task 1Building of synchronization panel (Implementation & Module testing phase) 0% WK 5 WK 11
Task 2Transportation and Panel Installation 0% WK 12 WK 12
Phase 4: INTEGRITY CHECKS ON TRANSFORMER & GENERATOR SETS
Sample phase title block
Task 1Integrity check on transformer unit 0% WK 12 WK 12
Task 2Integrity check on Generator units 0% WK 12 WK 13
Phase 5: RELOCATION OF GENERATOR SETS AND INSTALLATION OF CABLES
Sample phase title block
Task 1Relocation of generator sets to designated areas 0% WK 14 WK 14
Task 2Installation of cables between generator and installed panel 0% WK 14 WK 14
Phase 6: TESTING & COMMISSIONING OF SYNCHRONIZATION SYSTEM
Sample phase title block
Task 1Commissioning of Synchronization system 0% WK 15 WK 15
Task 2Reliability test and Hand-Over to client 0% WK 15 WK 16