GCP-32 and SPM-D - DSF Technologies

Application Sheet
51258
GCP-32 and SPM-D
Monitoring and Control of
14 Generator sets
Type of Plant
14 Caterpillar 100V/5A
gensets with a total output of
25,4 MW
Woodward Energy
Control Technologies
• Genset Control
Package GCP-32 (15)
At the end of
2004 the first 14-unit
synchronization panel controlled by Woodwards proven generator
set control package GCP-32 was installed for the
US-Army in Iraq. The work was completed in collaboration with
Emisan Ltd., an Istanbul, Turkey-based manufacturer of electrical
control panels, through Woodward’s Stuttgart, Germany, office.
Electrical System
The power plant is based on 14 Caterpillar 100V/5A gen-sets, with a total output of 25.4
MW. The generators differ in their power output. The 25.4 MW is composed out of eight
gen-sets with 2275 KW (CAT 35016 Diesel), four with 1250 KW (CAT 35012 Diesel), and
two with 1100 KW (CAT 3508 Diesel) power generation. The system is divided into four
groups, two with four generators and two with three generators. Additionally, a redundant
generator is installed to cover a potential breakdown of one of the other units.
Load
G
#1
G
#2
G
#3
#4
GW- 4
G #5 G
#6
GW- 4
G
#8
G #9 G
GW- 4
CANbus
Electrical System
#10
G #11
G #12 G
GCP–32
GCP–32
SPM-D 10
GCP–32
GCP–32
GCP–32
GCP–32
G #7
GCP–32
SPM-D 10
GCP–32
GCP–32
G
GCP–32
SPM-D 10
GCP–32
GCP–32
GCP–32
GCP–32
SPM-D 10
#13
GW- 4
G #14
• One breaker synchronizer
SPM-D10 (4)
• Gateway interface
converter GW-4 (4)
International
Woodward Industrial
Controls
PO Box 1519
Fort Collins CO, USA
80522-1519
1000 East Drake Road
Fort Collins CO 80525
Ph: +1 (970) 482-5811
Fax: +1 (970) 498-3058
Europe
Woodward Governor
Company LeonhardReglerbau GmbH
Handwerkstrasse 29
70565 Stuttgart, Germany
Ph: +49 (0) 711 789 54-0
Fax: +49 (0) 711 789 54-100
Distributors & Service
Woodward has an
international network of
distributors and service
facilities. For your nearest
representative, call the Fort
Collins plant or see the
Worldwide Directory on our
website.
Corporate Headquarters
Rockford IL, USA
Ph: +1 (815) 877-7441
The generators can
operate individually,
in smaller groups or
all together in isolated
or mains operation.
Each generator is
controlled by a
Woodward GCP-32
generator system
control and each of
the four groups is
synchronized by a
Woodward SPM-D
Automatic Synchronizing Control Panel
digital synchronizer.
Supervisory control is carried out by a Siemens
Simatic S7 automation system equipped with a
Siemens SCADA System for visualization. Data is fed
from the generator system controls by a Woodward
GW-4 gateway. An automatic synchronizing control
panel displays the positions of the breakers, the
voltage of the busbar, the electrical values of the gensets and any alarm messages. With this “Master
Panel” it is possible to manage the system manually.
Screen
www.woodward.com
/smart-power
Application
This document is distributed for
informational purposes only. It
is not to be construed as
creating or becoming part of
any Woodward Governor
Company contractual or
warranty obligation unless
expressly stated in a written
sales contract.
© Woodward Governor
Company
All Rights Reserved
- 05/7/S
In this application, if mains power is available, the system will be network supplied. In
case of loss of mains the mains circuit breaker opens and the supervisory control records
the last level system power purchase. According to this value, the required generators
plus one will start. First, the several groups are synchronized to the busbar, then the
active/reactive load sharing system takes control.
The operator defines the rated and backup power via the SCADA system, and then
based on those values, the supervisory control handles the load-dependent start/stop of
the generators. The allocation of the priorities of the gen-sets is calculated by the
supervisory control, based on the operating hour data imported from the GW-4 gateway.
In case of an overload condition, the generator load will be shut down according to the
predefined priorities of the SCADA system.
Conclusion
The commissioning and installation of the 14 gen-set system was successful, as the
GCP-32 worked efficiently with the range of gen-set sizes. The operation of the standard
GCP-32, SPM-D and GW-4 controls illustrated the adapability of Woodward controls to
this unusual application. The interaction of various controls enables reliable service from
the system. Woodward would like to thank Emisan Ltd. for their time and energy on this
project and congratulates them on a great control system.