easYgen-3000XT Series Training Sequencing

Introduction Multiple easYgen-3000s may be configured to sequence generators on- and offline in order to supply the power required while operating the power plant with a high degree of efficiency. This sequencing is performed automatically through a Load Dependent Start/Stop (LDSS) calculation in the easYgen software according to the thresholds configured by the user. This LDSS calculation may be utilized in utility parallel operation as well as for isolated operations.

Introduction Isolated and mains parallel operations Different size of engine ratings possible Reserve power or generator load calculation Multiple choice for start/stop priority selection Emergency mode start with “start all” or “sequencing”

Connection between the units via CAN 1 or Ethernet A Getting started Connection between the units via CAN 1 or Ethernet A Connection between the units via CAN 1 or Ethernet A CAN 1 Ethernet A

Activate the sequencing Getting started Activate the sequencing

Activate the sequencing Getting started Activate the sequencing Only generators on the same bus segment can be sequenced Load busbar 1 busbar 2 Load

Getting started Status screen - Operation mode and breaker feedback status - Add on/off condition - Measured values

Getting started Status screen

Multiple start/stop priority selection Assigned generator priority Efficiency, fit size of engine Based on maintenance hours Change of engines according to run time Assigned generator number (device number) 1 2 3 4 5

Start/Stop Priority 1 1. Base or alternative priority sequencing Lowest number has the highest priority Generator assigned priority Base priority Three alternate priorities (LogicsManager)

Start/Stop Priority 2 2. Fit size of engine sequencing For use with multiple engine sizes Calculation for optimal efficiency Start/Stop of multiple engines is possible Works only if the general priority is equal Base priority or LogicsManager

Start/Stop Priority 3 3. Fit service hours sequencing Equal – maintenance at the same time  Start unit with the highest service hours remaining  Stop unit with the lowest service hours remaining Staggered – different maintenance time  Start unit with the lowest service hours remaining  Stop unit with the highest service hours remaining Period of use hours- Engines are started/stopped based on operation hours  Maintenance counter has no influence Works only if the general priority (base or LogicsManager) is equal

Start/Stop Priority 4 4. Change of engines  Fit service hours = equal The easYgen-3000 divides the time remaining on the maintenance hours counter by the service hours group (32/64/128h) to determine the individual unit’s time group. Example: unit 1: 254 h  254 / 64 = 3.96  Time group 3 unit 2: 325 h  325 / 64 = 5.07  Time group 5 unit 3: 284 h  284/ 64 = 4.44  Time group 4 The unit 2 is the next unit to start higher calculated time group

Start/Stop Priority 5 2. Generator number Lowest device number -> highest priority

Start/Stop Priority Dead bus start mode (loss of mains condition) All All available engines will start and supply the load If the minimum running time is expired the LDSS sequencing calculates how many engines will be required to supply power to the load and sequences generators offline. LDSS Only one generator is started and closed to the busbar. The LDSS sequencing calculates if additional units are required and additional generators are sequenced online accordingly. Load sequencing schemes are typically used with this type of dead bus starting to prevent overloading the generator.

Start/Stop – Sort Priority “LDSS sort priority always” No: The sorting depending on operation time groups, priority and device number is executed only, if the load situation causes a new engine constellation.   Yes: The sorting depending on operation time groups, priority and device number is executed always. Note: The LDSS sort priority always – feature is only available for the “Reserve power” mode! Note: If the LDSS sort priority always – feature is disabled, the LDSS remains compatible to the first generation easYgen3000

Calculation System reserve power Generators are sequenced on and off by means of maintaining a spinning reserve for the plant. This reserve power threshold is utilized to calculate when additional generators are required to be started or shutdown. Utilized for system requiring high degree of reliability Switchable reserve power (2 reserve power settings in mains parallel mode and 2 settings in isolated operation mode Ensures that reserve is always available Reserve power must match the largest load step Most efficient when more generators are online Additionally the device provides a LogicsManager command variable, if the current Reserve power request is matched. This gives the operator the feedback to proceed with his process after requesting more reserve power.

System reserve power – Mains parallel Calculation System reserve power – Mains parallel Load P rated = 200 kW 70 kW 50 kW 20 kW Power setpoint Import 50 kW Minimum power 20 kW Reserve power 30 kW Hysteresis 10 kW Start of the first engine Actual mains power > power setpoint + generator min. load Actual mains power > 50 kW + 20 kW = 70 kW

System reserve power – Mains parallel Calculation System reserve power – Mains parallel Load P rated = 200 kW 220 kW 170 kW 50 kW 30 kW Power setpoint Import 50 kW Minimum power 20 kW Reserve power 30 kW Hysteresis 10 kW Start of the second engine Actual total generator power > Total rated power – reserve power Actual total generator power > 200 kW - 30 kW = 170 kW

System reserve power – Mains parallel Calculation System reserve power – Mains parallel Load P rated = 200 kW 420 kW 185 kW 50 kW 15 kW Power setpoint Import 50 kW Minimum power 20 kW Reserve power 30 kW Hysteresis 10 kW Start of the third engine Actual total generator power > Total rated power – reserve power Actual total generator power > (200 kW + 200 kW) - 30 kW = 370 kW

Calculation 220 kW 420 kW 620 kW Second engine starts third engine starts three unit without reserve Mains power Generator power Reserve power

System reserve power – Mains parallel Calculation System reserve power – Mains parallel Load P rated = 200 kW 410 kW 120 kW 50 kW 15 kW 5 kW Power setpoint Import 50 kW Minimum power 20 kW Reserve power 30 kW Hysteresis 10 kW Stop of the third engine Actual total generator power < Total rated power (n-1) – reserve power - hysteresis Actual total generator power < (200 kW + 200 kW) - 30 kW – 10 kW = 360 kW

System reserve power – Mains parallel Calculation System reserve power – Mains parallel Load P rated = 200 kW 210 kW 80 kW 50 kW 30 kW 10 kW Power setpoint Import 50 kW Minimum power 20 kW Reserve power 30 kW Hysteresis 10 kW Stop of the second engine Actual total generator power < Total rated power (n-1) – reserve power - hysteresis Actual total generator power < 200 kW - 30 kW – 10 kW = 160 kW

System reserve power – Mains parallel Calculation System reserve power – Mains parallel Load P rated = 200 kW 60 kW 50 kW 10 kW Power setpoint Import 50 kW Minimum power 20 kW Reserve power 30 kW Hysteresis 10 kW Stop of the last engine Actual total generator power < Minimum power - hysteresis Actual total generator power < 20 kW – 10 kW = 10 kW

Calculation

Calculation System reserve power – isolated operation Start condition First unit immediately The following unit uses the same formula like mains parallel Actual total generator power > total rated power – reserve power Stop condition The same formula like mains parallel Actual total generator power < total rated power (n-1) – reserve power - hysteresis Last unit keeps running

Calculation Generator load capacity Generators are sequenced on and off by means of monitoring the individual generator load. This permits the generator to be loaded to a designated maximum limit before the next generator is started. The dynamic parameter prevents the engine from an overload and permits the plant operating characteristics to be customized for three levels of efficiency. Simplified generator sequencing Most efficient when few generators are online

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 70 kW 50 kW 20 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% Start of the first engine Actual mains power > power setpoint + generator min. load Actual mains power > 50 kW + 20 kW = 70 kW

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 210 kW 160 kW 50 kW 40 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% Start of the second engine Actual generator power > max. load Actual generator power > 200 kW * (0.8) = 160 kW

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 370 kW 160 kW 50 kW 40 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% Start of the third engine Actual generator power > max. load Actual generator power > (200 kW + 200 kW) * (0.8) = 320 kW

Calculation 210 kW 370 kW 530 kW Second engine starts third engine starts three unit at max. load Mains power Generator power Reserve power

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 290 kW 80 kW 50 kW 120 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% Stop of the third engine Actual generator power < min. load Actual generator power < (200 kW * 3 ) * (0.4) = 240 kW

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 210 kW 80 kW 50 kW 120 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% !!! Stop of the second engine Actual generator power < min. load Actual generator power < (200 kW * 2 ) * (0.4) = 160 kW !!!

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 210 kW 50 kW 160 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% Second engine has the same start/stop point !

Calculation Generator load capacity Calculating dynamic power for remaining generator Dynamic characteristic= [(max power % – min power %) * dynamic] + (min power %) Dynamic power level = (dynamic characteristic) * (generator rated power) Constants: Low dynamic = 25% Moderate dynamic = 50% High dynamic = 75% Example for Moderate: Dynamic characteristic=[(80% – 40%) * 50%] + (40%) = 60% Dynamic power level = (60%) * (200 kW) = 120 kW

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 190 kW 60 kW 50 kW 140 kW Power setpoint Import 50 kW Minimum power 20 kW Max. load 80% Min. load 40% Stop of the second engine Maximum generator power after stop second engine < rated power * Dynamic Maximum generator power after stop second engine < 200 kW * 60% = 120 kW

Generator load – Mains parallel Calculation Generator load – Mains parallel Load P rated = 200 kW 60 kW 50 kW 10 kW Power setpoint Import 50 kW Minimum power 20 kW Hysteresis 10 kW Stop of the last engine Actual generator power < Minimum power - hysteresis Actual generator power < 20 kW – 10 kW = 10 kW

Calculation 290 kW 190 kW 60 kW Third engine stops second engine stops last engine stops Mains power Generator power Reserve power

Calculation Generator load– isolated operation Start condition First unit immediately The following unit uses the same formula like mains parallel Actual total generator power > max. load Stop condition The same formula like mains parallel Actual total generator power < min. load and dynamic Last unit keeps running

Exercise: Reserve Power Configure the load dependent start/stop for a mains parallel application with two peak shaving generators with reserve power sequencing (rated power 100 kW). Reserve power calculations: Mains interchange power set point Import 50 kW Start first generator at 80 kW Import power Second generator starts if first is above 70 kW Stop the second generator when both generators are at 25 kW What is the shutdown point for the last generator?

Exercise: Solution Configure the load dependent start/stop for a mains parallel application with two peak shaving generators with reserve power sequencing (rated power 100 kW). Mains interchange power set point Import 50 kW Parameter  Configuration  Configure application  Configure controller  Configure load control  Load setpoints  Load set point 1 source  (5539) Internal pwr. setp.1  Load set point 1 or 2  (5526) Import  Int. load control set point 1 or 2  (5520) 50 kW

Exercise: Solution Configure the load dependent start/stop for a mains parallel application with two peak shaving generators with reserve power sequencing (rated power 100 kW). Start generator at 80 kW Import power Parameter  Configuration  Configure application  Configure automatic run  Load dependent start/stop  Mains parallel operation Load set point 1 + MOP min load = Import power level 50 kW + MOP min load = 80 kW MOP Minimum load 30 kW

Exercise: Solution Configure the load dependent start/stop for a mains parallel application with two peak shaving generators with reserve power sequencing (rated power 100 kW). Second generator starts if first is above 70 kW Parameter  Configuration  Configure application  Configure automatic run  Load dependent start/stop  Mains parallel operation  MOP Reserve power  30 kW Generator rating - MOP Reserve power = next start 100 kW - MOP Reserve power = 70 kW

Exercise: Solution Configure the load dependent start/stop for a mains parallel application with two peak shaving generators with reserve power sequencing (rated power 100 kW). Stop the second generator when both generators are at 25 kW Parameter  Configuration  Configure application  Configure automatic run  Load dependent start/stop  Mains parallel operation MOP Hysteresis  20 kW

Exercise: Solution Configure the load dependent start/stop for a mains parallel application with two peak shaving generators with reserve power sequencing (rated power 100 kW). What is the stopping point of the last engine ? Generator load < (MOP minimum load) – (MOP Hysteresis) Generator load < (30 kW minimum load) – (20 kW Hysteresis) Last generator shuts down at 10 kW

Exercise: Generator Load Configure the load dependent start/stop for an isolated plant with three generators with generator load sequencing (rated power 100 kW). Generator load calculation : Second generator starts if first is above 70 kW. At what power level does the third generator start? Configure the plant so that the third generator will shutdown when the plant load reaches 90 kW. At what power level does the second generator shutdown when the dynamic is configured as Moderate (50%)?

Exercise: Solution Configure the load dependent start/stop for an isolated plant with three generators with generator load sequencing (rated power 100 kW). Second generator starts if first is above 70 kW. Parameter  Configuration  Configure application  Configure automatic run  Load dependent start/stop  Isolated operation  IOP Max. generator load (5762)  70%

Exercise: Solution Configure the load dependent start/stop for an isolated plant with three generators with generator load sequencing (rated power 100 kW). At what power level does the third generator start? Plant load > Generator rated power * # generators online * IOP max generator load (5762) 100 kW * 2 generators online * 0.7 = Next start 100 kW * 2 generators online * 0.7 = 140 kW

Exercise: Solution Configure the load dependent start/stop for an isolated plant with three generators with generator load sequencing (rated power 100 kW). Configure the plant so that the third generator will shutdown when the plant load reaches 90 kW. Generator min. load = Plant min. load / # generators online Generator min. load = 90 kW / 3 = 30 kW Generator min. load / Generator rated power = IOP min generator load (5763) 30 kW / 100 kW = 0.3 or 30%

Exercise: Solution Configure the load dependent start/stop for an isolated plant with three generators with generator load sequencing (rated power 100 kW). At what power level does the second generator shutdown when the dynamic is configured as Moderate (50%)? Generator min. load * # generators online = Plant load at shutdown request 30 kW * 2 = 60 kW (continued)

Exercise: Solution Configure the load dependent start/stop for an isolated plant with three generators with generator load sequencing (rated power 100 kW). At what power level does the second generator shutdown when the dynamic is configured as Moderate (50%)? (continued) (Gen max. load – Gen. min load) * (50%) = Dynamic characteristic (70 kW – 30 kW) * (0.5) = 20 kW Dynamic characteristic + Gen. min. load = generator dynamic (5757) 20 kW + 30 kW = 50 kW A shutdown will be evaluated but will not be permitted until the load drops below 50 kW.