HHP Natural Gas Engine & Generator Controls

MODULE 2

SAFETY & ISOLATION

Genset Information Labels

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 2
 Risk Assessments
A MUST before any work commencement to provide safe working at all times.
•Performed by a competent person with authority to implement the required safety
measures:
• Job Planning (people + place + tools + time)
• Personnel Selection (Required Skills Definition)
• Adequate Work Space & Lighting

• Method of deactivating the equipment

• Can you prove that the equipment is isolated / dead?

• If working on live equipment, question why:

• Is the risk reasonable?
• Can the task be accomplished on isolated / dead equipment at some other time?
• Is the right PPE available at the work site?

•If the risk assessment is conducted by someone other than yourself – perform your own
risk assessment & keep a record.

When working Æ strictly adhere to & enforce the mitigation tasks

resulting from the assessment.
CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 3
 Work Permits
Almost always required before even visiting a site!

Required Personnel Permit Types:

ƒ Access: Not undertaking work on plant equipment (cleaning, painting, etc.)

ƒ Work: Routine service / maintenance / repair tasks on plant equipment
ƒ Note: Separate permits required for HV systems lock-out.

ƒ Hot Work: Naked flames / heat generating equipment required in plant.

ƒ Sanctioned to Test: Energized systems required for tests by means other than its
normal source, e.g. MEGA. Also allows for the removal of safety devices for purpose of
testing.

ƒ Confined Space: Tasks in confined spaces with risks of fume accumulation, etc.

Obtain these permits from the plant or plant safety supervisor before
departing to work on site.

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 4
 Operations Safety

Plant operations manager may authorize work

commencement if:
1. No fuel lines or other power sources open
2. No voltages present
3. Check safety and power dissipation or
retaining devices
4. Check that the circuits have been bled

Ensure that everyone concerned knows what is & isn’t

within your control!

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 5
 Genset Lock-Out Procedure

• Stop Genset: Press Stop button on HMI320

to lockout Auto/ Manual control modes.

• Isolate Fuel Supply: Close & lock in

closed position the manual gas valve.

• Isolate VDC: Set & lock SDC switch “OFF”

• Isolate VAC: Set & lock ISO switch “OFF”

HMI320 - Stop

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 6
 Genset Lock-Out Procedure
GIB Internal Components – Customer Connection Panel

GIB w/ Customer Connection panel door open

• Short the CT’s: Via the shorting
block’s – short the PCC3300 Utility
Sensing CT’s to drain residual energy.

Shorted
Position

Normal
Position
Customer
• Switch off ECM’s: Switch Terminal
SMCM to “O” (off). Strip
CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 7
 Genset Lock-Out Procedure
GIB Internal Components – Primary Panel

GIB w/ Primary panel doors open VAC Terminal Rail

VDC Terminal Rail

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 8
 Genset Lock-Out Procedure
GIB Internal Components – Primary Panel
VAC Rail Isolation

1 2 3 4 5 8 6 7

MCB’s
• Lock-out:
• VAC Isolation: Switch all VAC Once in the off
Rail Circuit Breakers / Contactors to position, MCB’s
the Off / Open position. 1Æ5 & 8 can be
locked off.

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 9
 Genset Lock-Out Procedure
VDC Source Backup Isolation

• Cover

• Battery Pack (x2)

• Genset Skid

VDC Source Backup w/ Cover On VDC Source Backup w/ Cover On

Side Profile

• Fuse Isolation Holder • VDC Source Backup

Isolation: On both battery
• Fuse Active Holder packs, remove all fuses from the
active holder & store them in the
isolation holder.

Battery Pack CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 10
Genset Lock-Out Procedure
Tag Out

Out of
Service

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 11
 Genset Lock-Out Procedure
Engine Isolation

Electric Starting
• Remove Battery Charger: Switch-off then disconnect
the engine starter’s VDC supply (battery) charger.

• Remove Battery Leads: Disconnect the leads from the

engine starter’s VDC supply (battery).

Pneumatic Starting
• Isolate Air Supply: Isolate the air supply from the start Electric Starter Interlock
air compressor to the engine starter. If possible, secure the
isolation tap in the closed position.
• An isolation tap should be found @ the air outlet of the air
receiver cylinders.

• Vent Air Supply Line: Vent the engine starter air

supply line.

CAUTION: Supply Air Pressure ~ 40 Bar (580 psi)

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 12
 Genset Lock-Out Procedure
Final Steps

DANGER:
‰ Double Check: Ensure the alternator mains & VAC supply is isolated and locked out. This must
be done by a competent, authorised person ONLY.

‰ Permit Check: Check to ensure you have the permits required for work and testing. Obtain
written authorization / clearance.

‰ Local Authority: Follow local electrical & plant safety rules.

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 13
 Common Electrical Grid Ratings
400,000 Volts (EHV) (Recommended safety radius 3.1m)

275,000 Volts (EHV) (Recommended safety radius 2.4m)

132,000 Volts (Recommended safety radius 1.4m)

66,000 Volts (Recommended safety radius 1.0m)

33,000 Volts (And below, recommended safety

radius 0.8m)
11,000 Volts

High Voltage Voltage

1,000 Volts Low Voltage Classification
0 Volts
Ground Potential
DANGER! High voltage will jump large distances to any part of your body or ground conductor.
CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 14
 Common Electrical Safety
AMPERES
SEVERE BURNS 6 AMPS TO A
1.0A
SOLENOID!
BREATHING STOPS

0.2A DEATH
200mA
DIFFICULT
HUMAN BODY
BREATHING RESISTANCE
0.1A
APPROXIMATELY
100mA
5,000 ohms
OUCH! SAFETY VOLTAGE IS
0.04A CONSIDERED AS 50V.
IT TINGLES THIS WOULD RESULT
40mA
IN A MAXIMUM
0.001A Possibility of CURRENT FLOW
1mA DEATH THROUGH THE BODY
OF:
CAN JUST FEEL IT
50/5000 = 0.01A (10mA)
CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 15
 Common Electrical Safety
Final Work Safety Precautions

ƒ Always isolate and lockout the voltage supply

ƒ Display isolation notices

ƒ Only work on apparatus that you are authorised to

ƒ Follow local safety rules & permit to work systems

ƒ Keep one hand in your pocket when working with electrical equipment to
prevent accidental contact with ‘live’ or ‘earthed ’ components.

ƒ Ensure all electrical cables are:

ƒ Properly Supported
ƒ Protected Against Shocks + Stresses + Abrasion
ƒ Using flexible or solid cable trunking and / or cable ties

ƒ If in doubt - DON’T DO IT, ASK!

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 16
 Natural Gas Safety
Human
Asphyxiation
LEL UEL

4% 12.5% 16%

COMBUSTION WINDOW

• REMEMBER! The Genset performs a Natural Gas

VENT CYCLE on the next start attempt 3x Lighter than Air
following any E-STOP. Colorless & Odorless

• FIRE? Æ CO2 or Dry Powder Fire

Extinguishers only
Air

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 17
 Team Task
Show you know..
Rules of Natural Gas Safety from CVC 4091824

1. Identify the common properties of Natural Gas…

CUMMINS, INC TRAINING - Gas Engine Controls / Safety / KDL / 10 - 2009 / REV 1.1 18
HHP Natural Gas Engine & Generator Controls

MODULE 2

SAFETY & ISOLATION

END