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POWER STATION STANDBY DIESEL GENERATOR SYSTEM CONTROL &

AUTOMATION USING PLC

Article · June 2019

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131

POWER STATION STANDBY DIESEL GENERATOR SYSTEM CONTROL &

AUTOMATION USING PLC

R.Karthick1,A.SathishKumar2,K.Rajavelu3
1,3
Assistant Professor, Department of Electrical and Electronics Engineering, CK College of Engineering and
Technology, cuddalore, Tamilnadu, India. [email protected]
2
Assistant Professor, Department of Electrical and Electronics Engineering,Saveetha School of Engineering,
Saveetha Institute of Medical and Technical Sciences, Chennai, Tamilnadu, [email protected]

ABSTRACT

This paper deals with industrial oriented Diesel Generator used as Auto Main Failure System in NLC
Thermal Power Station – II. The system is capable of power supply at the rate of 0.4KV.The 0.4KV
emergency buses are being monitored with the help of CT’s and PT’s through protection relays. If the fault
occurs in the supply are load, the emergency bus feeding breaker trips and diesel generator gets started. The
whole function of the circuit is controlled by using PLC including protection activities and also
consideration for safe starting, synchronization, protection against electrical and mechanical faults of the
generators in the software used for the PLC.
Keywords— PLC, Diesel Generator, NLC microcontroller

INTRODUCTION

In NLC Thermal Power Station – II there are 7 units available. Each unit is rated for 210MW and it consists
of a boiler, a turbine and a turbo-generator of its own. Total Power of (7×210MW) can be transmitted to
grid. Each unit has an AMF system with a DG set to supply 0.4KV to the emergency load. The emergency
bus should be monitored always for any voltage failure (less than 80%).At any case of failure the emergency
bus supply should be restored within 17 secs through a DG sets for effective unit generation. In case of any
problem in DG set of concerned unit automatically with a pre-fixed delay, adjacent unit DG set will come
into service to safe–guard the emergency bus of other units. Totally four DG sets are available for stage-II
units. The unit DG SET with its associated circuit breakers operation according to logic requirements. In the
present manual operation of auto main failure system has the following drawbacks:
 The increase in number of relays makes the wiring complex.
 Physical wiring of system is complicated and difficult.
 The panel board arrangement occupies more space.
 It cannot be switched on and off at high speed.
The main objective of this paper is to design and implement a PLC based automation controlling operation
for a D.G system in NLC Thermal Power plant T.S-II. Early years they are using complicating numbers of
relay elector mechanical relays and timers operation control over monitoring 0.4 KV system. Our aim is to
continuously charge the 0.4KV system by using AMF system, our purpose is to starts the D.G set whenever
the system failures. They find uses in a wide variety from hospitals, scientific laboratories, data centers,

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131
telecommunication equipment and modern naval ships, Airports, small and large scale Industries. The
power quality improvement in a diesel generator (DG) set-based standalone supply system feeding three-
phase four wire (3P4W) loads. The voltage of the DG system is controlled by excitation control of the
synchronous generator [3].The frequency is controlled by speed regulating system of the diesel engine. The
speed of the engine is regulated by controlling the fuel injection of the diesel engine [7,8]. Laboratory tests
were needed to carry out on seven voltage monitoring relays to determine their operational characteristics
and ensure their impact of identical power quality on different voltage utilization[6].There are fixed speed
system with synchronous generator, adjustable speed doubly fed induction generator (DFIG) and adjustable
speed system using brushless permanent magnet generator in the thermal power plant. The control strategy
of Sinusoidal PWM (SPWM) was implemented to drive the adjustable speed system of induction and
synchronous generator[4].

Power reliability modelling and evaluation of emergency in the standby power systems needed to ensure
continuity of load power in case of mains outages or faults in power generating and distribution
systems[1].Protective Relaying is important in the Stand by Generation Systems[2] which product from short
circuit faults and abnormal load conditions. Microwave relay systems throughout the country has shown that
involuntary outages have been caused principally failure of the input power to the microwave equipment.
This emergency power is supplied by an emergency generator set at the microwave station
site[5].Controlling of the robot movement and reduction of error occurrences in robot arm system by using
IQGA nonlinear evolutionary algorithm improve the efficiency in the automative system[9].

KV SYSTEM LAYOUT

2 Number of Units Service Transformer of 1600 KVA named UST-A &B normally energizes the UNIT 0.4
KV system buses A&B. UST-A feeds USS-A whereas UST-B feeds USS-B. (USS- Unit Service Switch-
gear). UST-A availing its 6.6 KV supply from the respective 6.6 KV unit bus –a through MOCB. The LT
side (415V) of this transformer is connected to USS-A through an ACB (Normal Incomer).The connections
UST-B is similar to that of UST-A except that it gets its 6.6 KV supply from the respective 6.6 KV unit bus-
B and the LT side is connected to USS-B. Both the buses can be inter connected through a Bus Coupler
(B/C Breaker) which is normally in open condition. Normal / Emergency switchgear is provided at both the
buses. The normal and Emergency sections will be serviced by the Normal I/C breakers-A or B.

The Bus-coupler will be in open. The significance in Normal and Emergency bus connected loads are, the
supply for Normal Bus loads are not much important (alternate pair is available in Bus-B Normal Bus) for
unit running or power generation. But supply should be always available for Emergency bus sections,
because the connected loads plays vital role in Power generation and even the unit is not running the
connected loads needs supply for its emergency functions. Hence the Maximum allowable time of supply
disturbance is only 17 second. Differential pressure at 0.84 Kg/cm2 between the airside seal oil pressure and
hydrogen pressure. The hydrogen side seal oil pump receives its supply from the hydrogen side seal oil flow
chamber. It pumps part of this through seal oil cooler to the hydrogen side of the seal ring.

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131
Table 1: Some of the Loads Connected With Emergency Bus and its Importance

Power BMR
Equipment Rating Fuse (OLR) Remarks
Name (KW) (A) Setting (A)
Shaft Turning Rotate Rotor at low speed
18.4 63 30
Gear Motor prevent from bending
Turning Gear Oil
11 63 25 lubricate turbine bearings
Pump

Vacuum Breaker
0.23 6 1.1 To adjust vacuum condenser
Valve

Table 2: List of Loads Connected to Emergency Bus

Power
Equipment Name Rating Remarks
Fuse (A)

Supply To Siemens Panel To supply 110v AC for control and

5KVA
JCO-6 instrumentation supply.
Test Supply Transformer
2KVA 25 To check the healthiness of Module
(415/415.2 KVA)
To float charge battery system and supply
Unit Battery Charger 200A 200 220V DC for essential loads and control
supply
UPS Main Charger-1 To float charge battery and supply 110V
250A 250
(55 KVA) AC for control and instrumentation supply
UPS-3 Source-1 To float charge battery and supply 110V
250A 250
(FCB Power Supply) AC for control and instrumentation supply

AUXILIARY OIL PUMP

Auxiliary oil pump comes in to service to maintain lubrication in the event of turbine tripping. When
turbine shaft speed decreases below 1200 RPM, this AOP comes to restore. Induced drought fan (ID) and
forced draught fan drivers are above 500KW and driven by 6.6 KV supply (H.T) due to its higher capacity
and continuous operation chance of heating is more. Hence all the above drives are cooled through two lub
oil drives/drive connected in 0.4 unit bus. The ID and FD fan drivers will run only when the lub oil system
is healthy otherwise they will trip and hence suddenly power generation will be reduced to minimum level.
Each ID/FD fan drives has two lub oil pump drives, one will be in 0.4 Kv bus A and other bus B.

LOP-LUB OIL PUMP DRIVES FOR ID/FD FAN DRIVES

Induced drought fan (ID) and forced draught fan drivers are above 500KW and driven by 6.6 KV supply
(H.T) due to its higher capacity and continuous operation chance of heating is more. Hence all the above
drives are cooled through two lub oil drives/drive connected in 0.4 unit bus.

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131
The ID and FD fan drivers will run only when the lub oil system is healthy otherwise they will trip and
hence suddenly power generation will be reduced to minimum level. Each ID/FD fan drives has two lub oil
pump drives, one will be in 0.4 Kv bus A and other bus B.
AMF SYSTEM

The fundamental purpose of the AMF controller is to allow automatic operation of stand by generator.
The AMF continually monitor the mains supply and it starts the generator it there is a disruption in the
supply.The AMF will then run and monitor vital engine and alternator parameters, while the supply
interruption continues. The generator will automatically be stopped by the AMF once the main supply has
been restored to within acceptable limits.AMF panel is the short form of auto main failure panel.

It normally connected to the generator set to control the generator set function. It can call the generator set if
the AMF further connected to the main switch board (received power from the other source normally from
the local authority) which equipped with auto transfer switch/automatic change over contactor. While
normal supply serve to main switch board failed, the AMF board will send the power failure signal to
generator set. Then the generator set will run and serve the supply to main switch board. Auto Main Failure
System is one which has its own diesel engine connected with an a .c generator.

The system is capable of supply power at the rated of 0,4kv each unit has one such D.G set arrangement to
supply power at the rate of 0.4kv to emergency loads in case of problem in normal 0.4 k v supply. Absence
of 0.4kv supply in emergency bus may affect unit power generation either partially or totally in some worst
cases. Without supply in emergency bus the unit (boiler-turbine-generator) operation will be in risk.

NORMAL / EMERGENCY BUS AND DIESEL GENERATOR SET 04kV

The 0.4kv system normal and emergency bus is being monitored all the time by CT’s and PT’s through
protection relays. If the fault occurs in the supply or load, the emergency bus feeding breaker trips and the
concerned diesel generator gets started. The whole function of this circuit is controlled by using plc logic is
networked modular PLCs. Here we are going to present our project using modular plc based one. Thermal
power plant has many auxiliary loads in addition to main constituents of the plant such as Boiler, Turbine
and Generator. Hence, the power supply is required to keep these auxiliary loads in running condition
whether unit generator is producing electrical power supply or not. Even to start power generation, we first
have to start auxiliary loads. In general, auxiliary loads are normally pumps, mills, fans, lighting, air
conditioners, conveyor system, motor operator valves and dampers and many such loads. Ratings of these
loads, all loads in variably require electrical drives called motors.The capacity of motors may vary from
several kilo-watts to some mega-watts. Depending upon the capacity of motors, their operating voltage
levels are also changing. As a thumb rule, generally, motors with capacity up 125KW are being operated at
3-phase, 415v and 50HZ power supply. Whereas, Motors with capacity more than 125KW are normally
connected to high voltage sources like 1.1KV or 3.3KV or 6.6KV, 3 phase, 50 HZ system.In Thermal Power
Station-II, drives for auxiliary loads are grouped in to two voltage levels. One group of drives are operating
at 415V A.C sources and are called Low Tension Loads and are simply called L.T. loads.Other groups of
drives are operating at 6.6KV A.C. sources and are called High-Voltage Loads and similar called
H.T.loads.Depending upon the capacity of motors, their operating voltage levels are also changing.

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131
As a thumb rule, generally, motors with capacity up to 125KW are being operated at three phase, 415KV
and 50HZ power supply. Whereas, motors with capacity more than 125KW are normally connected to high
voltage sources like 1.1KV. The 415V, 3Phase, 50Hz ac power supply is called as 0.4KV source and the
system dealing with this source is called as 0.4KV system. For each unit, two 0.4KV buses are available and
are identified as 0.4KV bus-A and bus-B. In addition to this to 0.4KV buses, one more 0.4KV bus called
emergency bus is always available.

CONTROL OF AMF SYSTEM PANEL

Figure 1: AMF Panel based control of D.G set

The circuit shows the design of AMF system control. Here Auto and Manual starting modes are available
through AUTO-MANUAL selector switch. If the selection is in auto, it will monitor 0.4 KV bus system
under-voltage faults When u/v occurs immediately Relay PR-1 will be energized and subsequently Fuel

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131
solenoid, Start solenoid, Cranking operation, DC excitation supply for 3 seconds through relay
AC4.Cranking operation will be governed by the timer T-2 which is a cyclic timer, having 5 sec On and 5
sec OFF periods for 30 seconds controlled through timer T-3. Timer T-1 is the DG set stop timer. When DG
system is decided to stop, it will be done manually through Manual stop PB.However Auto stop command
also available, it was not interlocked at present. The LOP will come into service immediately on the starting
of Diesel engine and if not the set is running it will be started for 30 sec once in 8 hours. This is being done
with the help of timer T-7, which is an Off-Delay timer. Once the DG is started in Auto and Generator
develops more than 80% of rated voltage and frequency, then the control given over to PRL-X relay, called
Synchronization circuit. After ensuring the o/p of this circuit- the Main I/C breaker closes, thereby ensuring
supply to DG PCC bus.After that the cooling system drives like, the present way of control employs electro-
mechanical relays and timers in AMF SYSTEM control. The control circuit uses control relays like PR-1,
PR-2 and PR-3, K-6, K6Aand so on. In addition to that Number of timers are also involved in the control
circuit addressed as T-1, T-2, T-3 and T-6.Due to the de-merits in the Existing Working Technology,
monitor and control AMF function with the help of PLC system is proposed. The Instant Advantage is the
Total Control Wiring is Being Converted as User-Friendly Software and PC friendly monitoring and control
facility A PLC works by continually scanning a program. We can think of this scan cycle as consisting of 3
important steps. There are typically more than 3 but we can focus on the important parts and not worry
about the others. After the third step the PLC goes back to step one and repeats the steps continuously.

RESULTS AND DISCUSSION

INPUT:
Efficient operation of v/g and f/g
Io :I/C-A BREAKER ON(PB)
I1 :I/C-B BREAKER ON(PB)
I2 :EME-A BREAKER ON(PB)
I3 :EME-B BREAKER ON(PB)
I4 :BUS-A U/V RELAY E/B
I5 :BUS-A NDR RELAY E/B
I6 :BUS-B U/V RELAY E/B
I7 :BUS-B NDR RELAY E/B
I8 : AUTO SELECTION
I9 : U/F FAULT IN DG BUS

CONCLUSION

The monitoring and control of DG set in the Stage-II power unit (0.4 KV system) using PLC is
replaced the existing relays, timers and associated devices which is the manual control system. The
significance of PLC in this DG set control system has been realized using ZEN software and the entire
control process was simulated & results were proved the accuracy of the PLC based control system. While
implementing PLC, it is quite convenient to control the elements by circuit breakers, motors etc. Due to the
superior communication facility with PC, the entire control system monitoring via computer is made
possible and this ensured the technology in widespread used in process control engineering applications.
Based on the simulation on hardware and software result, it’s proved that the PLC makes the system control
with high reliability, relatively at faster speed of data transfer compared to other available technologies and
consumes very less power for its operations. Related software uses Ladder language for 0.4KV bus
monitoring/D.G starting via AMF panel and associated D.G system

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JASC: Journal of Applied Science and Computations ISSN NO: 1076-5131
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