documenting and programming a complex sequence of...
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Page 1
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Documenting and Programming a
Complex Sequence of Operation
Presented
By
Michael E. Pincus, PE
Kohler Power Systems
Page 2
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Water Treatment Plant
Page 3
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Single
LineSequence Controls Structure
Path to Success
Why?
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The Single Line
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Sequence of Operation
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Nine (9) Common Configurations
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Type 900
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Some “what ifs” to think about
• Generator failure
– Out of service
– Does not start
– Fails after in was running
– Becomes overloaded
– Pre alarm
• Breaker failure
– Fail to open
– Fail to close
• Control system failure
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
This is the way I was taught to write a sequence
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
#@!?
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
There had to be a better way
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Initial
StateEvent Step 1
Step 2
Step N
Final
State
Current
State
Fail
Done
Current
State
Fail
Current
State
Fail
Done
Done
How every system works
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Simple Example
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The System
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
32 Possible States
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
152_M 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
152_1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1
T1/T2 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
252_1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1
252_M 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Page 16
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
A sequence is a transition from current state to new state
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Can One Document do it All?
– Submittal Sequence of operation
– PLC Programming instructions
– FAT (factory acceptance test) document
– SAT (site acceptance test)
– Final O&M manual
Page 18
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
How to describe the transition
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
What if something goes wrong?
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The “sequence” is a series of charts
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
PLC Programming
• Very easy to program and troubleshoot the system behavior
– Based on breaker position
• System does not get “confused”
– We can see the history
• Very easy to modify a sequence
– Only thing effected is that one sub routine
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Operator Interaction with System
• Stuff on the doors
– HMI – Human Machine Interface
• Touchscreen
– Meters
• Analog
• Digital
• Power quality
– Switches
• Control
– Remote control
– Remote monitoring
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Easy to operate
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Generator Controls
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
PLC Program
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
What Just Happened?
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Water Treatment Plant
Page 28
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Single
LineSequence Controls Structure
Path to Success
Why?
Page 29
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The Single Line
Page 30
Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The “sequence” is a series of charts
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Controls
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
Structure – Power Section
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The sentence that…….
Submit complete documented PLC ladder logic program to
implement the generator start, paralleling and synchronization, load
shedding, source transfer, etc., as described herein and as shown
on the drawings.
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Emergency Power System
Sequence of Operation
IEEE Atlanta – IAS Chapter
October 19, 2015
The Water Treatment Plant