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Head Office46, Jalan Saujana 2, Taman Industri Saujana, 09600 Lunas Kedah, MALAYSIATel: +604-484 7252 Fax: +604-484 9646 E-mail: [email protected]
KL Office2B, Jalan BRP 1/2, Bukit Rahman Putra, 47000 Sungai Buloh, SelangorTel: +603-61413400 Fax: +603-21784569 E-mail: [email protected]
www.topazit.com
TOPAZ INTEGRATED TECHNOLOGY SDN. BHD.
Power System Simulator:Power Management System for Students
Training and Experimental Lab
Contents
► Introduction 1
► General Overview of Power System Simulator ISB-2000 2
► SystemStandardConfiguration&Specification 5
► Generator Control Panel 6
► Load Modules 9
► MeasuringDetail 11
► SCADASystem 12
► Laboratory Layout 17
1
Withourextensiveexperience in industrialelectricalpowersystemsmanufacturingandservicing,wearepleased to offer an Industrial Type Power SystemSimulator. This simulator system serves a vital rollin hands-on training of engineering students fromvarious technicalfields, includingPower,Energy,Oil&Gasandmanufacturingindustries.
Thesimulatorhasbeendesignedandmanufacturedtoenablestudents toparticipate inpractical trainingwith realistic industrial environment. They will learntroubleshooting methods, how to make correctdecisionsundervariousreal-lifeoperatingconditions
and situations. Real-time effects can be demonstrated afterthestudentshavebeenpresentedwiththeorybytheirrespectedlecturer.
Thesimulatorsystemcomprisedofhardwaremodulesand software components, including overloadprotectionandsafetyfeatures.
Wealsoprovidecompleteengineeringpackage thatincludesdesign,manufacturing,installation,testing&commissioning,documentation(manual,drawingandproduct catalog), training, warranty and after salesservice.
Introduction
42
The Power System Simulator block diagram isprovidedinthefollowingpage.Mainelectricalpowerof theSimulator comes from415VAC, 3phTurbineGeneratorSet#A andaTurbineGeneratorSet#Bpower supply. The power generation is representedby 3 phase 20KVA Generator driven by 3P/15KWAC Motor simulating a turbine motor. The turbine/generatorcanbemanually/autosetbyusingVFDforvariousKW/HZcharacteristics.
The power cables are connected to SynchronizingControl Panel. The Synchronizing Control Panelis designed and manufactured to meet powersystem requirements. The panel is equipped withmicroprocessorbasedSynchronizerunit (WoodwardEasyGen3000),with24VDCbatteryandcharger.TheSynchronizerisusedtoparalleltheTurbineGeneratorSet#AwiththeTurbineGeneratorSet#Bpowerbus,with AMF feature. Power circuit breakers (MCCB)canonlybeclosedifbothvoltagesaresynchronous(coincident). Otherwise, faults in line operation,loadingoftheTurbineGeneratorSetand,inextremecases, damage to the generators can result. TheGenerator/Synchronizing Control panel is built withprotectionand safety features toensurea safeandreliable synchronizationasamonitoringelement formanualparalleloroptionallyasanindependentfully-automaticsynchronizingunit.
The MCC/MSB Panel serves as power supplydistributioncentrewithoutgoingcables to the loads.Itisanassemblyofdistributionpanels,eachofwhichcontainsswitches,meteringandbreakers thatallowelectricity to be redirected to appropriate loadswithprotectionandsafetyfeaturesbuiltin.
Features:• Microprocessor based Synchronizer.
SoftwareforPCtool(optional)• ItsendstheclosingcommandtotheMCCB
attheexactmomentofphasecoincident• Itperformsprogressivefunctionofverifying
voltage and phase angle conditions andensuring that theyarewithinpreset limits,beforeallowingtheACBtoclose.
• Generator and bus load metering suchas Amp Meter, Voltmeter, Freq. Meter,KW, PF,KWH, Double Volt, Double Freq.,Synchronoscope.HighaccuracyAnalogue/Digitalmeters(optional)
• ProtectionsuchasU/V,O/V,E/F,O/C• The panel is provided with local control
switches and indicator lights on the frontpanel
• PanelenclosureratingdesignedtoIP44 TheLoadbanksareprovidedforsimulation
of actual operating loads. Three types ofloadbankareprovided;resistive,capacitiveand reactive loadbank. This ensures realsimulation of various types of operatingloads.
Avarietyoftrainingschemesinclude:• Powermanagementstaff• Operatorofpowerplantsorsub-station.• Maintenancepersonnel• Teachingofstudent.• Researchinuniversities.
General overview of Power System Simulator ISB-2000
53
TheSimulatorsystemconsistsof;
Power Plant Generation Module►TurbineGeneratorSet(TGS)
• SynchronizingControlPanelwithAMFfeatures• ProtectionRelay• MCCB,Indication instrument and other
components corresponding to industrialswitchboard unit.
Motor Control Centre / Distribution Board►Over Current Protection Relay, Earth Leakage
Relay.• MotorStarter• ProtectionRelayandIndicationinstrument.
Load Module►Loadbanks:Resistive&ReactiveType.
SCADA►Provides simulation of power management
solution
4
System Block Diagram
Turbine Generator SetControl and
Synchronizer Panel
DCS /SCADAWorkstations
POWER PLANT GENERATION
TRANSMISSION LINE
RS485
ION 7330 ION 7330RTU
RTU
RTU RTU
SCADA JunctionBox
TCP / IP
ACMOTOR
LOAD BANKRESISTIVE
LOAD BANKREACTIVE
LOAD MODULE
Note:
TCP / IP
RS485
TRANSMISSION LINE
RECEIVINGMSB/MCC
GEN. SET A
GEN. SET B
VFD
VFD
TURBINE
TURBINE
GENERATOR
GENERATORWoodwardEasyGen
ION 7650
5
POWER GENERATION WITH SYNRONIZING PANEL
Switchboard for the power plant simulator includingthemotorgenerator,currentandvoltagetransformer.Protection relays, indicators, A-B busbars. Two ormoremotorgeneratorsectionscanbeconfiguredasanoption.
Optionsofmotorgenerator;
Thepowergenerationisrepresentedbythree-phase20KVASynchrounousgeneratordrivenbyACmotoras a turbine.
Theturbine/generatorcanbemanuallysetfordifferentKW/HZcharacteristic.
RelayProtectionforGeneratorandTransformer• DifferentialRelayProtectionforturbine/generator.• Overcurrentrelay.• Overvoltagerelay.
The operation mode of turbine/generator can bechoosen manual or automatic.
SystemStandardConfiguration&Specification
Continuous Output Rating 20KVA,16KW,0.8PF,3 PhaseWye, 415 VAC ,50 Hz, rated at1500RPM.CurrentRating:28Amperes.SystempowerEfficiency:Approx.80%OutputFrequency50Hz.
6
Power synchronizing – frequency, voltage viaAuto/Manual mode. It performs progressive function ofverifying voltage and phase angle conditions andensuring that they are within preset limits, beforeallowingtheACBtoclose.
GeneratorControlPanelwithAutomaticMainsFailure(AMF)startupScheme;
Whenever the busbar of the MCC does not have voltagetheTNBsupplybreakershallbeautomaticallyclosed.Throughthesynchronizercheck,theMCCB
canbeclosedwhenit issafe.ThentheDEGwillbeconnected to the MCC busbar.• SyncCheckRelay• Frequencymeter(45~55Hz)• Voltmeterscaled0-600V.• Synchronizing lamps to be wired such that the
lampsarebrightatsynchronism.• Operationmode:Auto,Stop,ManualandLoad/No
Loadtestmodesviadiscreteinputpossible.• Breaker control: Slip frequency/Phase matching
synchronization, open-close control, breakermonitoring.
Generator Control Panel
7
• Load transfer feature: open/closed transition,interchange,mainparallel.
• Remotecontrol via interfaceandanalog input foradjustingspeed,frequency,voltage,power,reactivepowerandpowerfactorsetpoint.
• Complete integrated engine and generatorprotectionaswellasmainsmonitoringfeatures.
• FreelyconfigurePIDcontrollers.• Configure trip level/delay timer/alarm classes for
monitoringandprotectivefunctions.• Microprocessor basedSynchronizer. Software for
PCtool(optional)
• It sends the closing command to theACB at theexactmomentofphasecoincident
• Itperformsprogressivefunctionofverifyingvoltageandphaseangleconditionsandensuringthattheyarewithinpresetlimits,beforeallowingtheACBtoclose.
• Generator and bus load metering such as AmpMeter, Voltmeter, Freq. Meter, KW, PF,KWH,DoubleVolt,DoubleFreq.,Synchronoscope.HighaccuracyAnalogue/Digitalmeters(optional)
• ProtectionsuchasU/V,O/V,E/F,O/C
8
DCS CONTROL AND MONITORING SYSTEM
Controlofsetpointsandmodesofoperationfor generator unit with automatic voltageregulation.
The followinganalysis shall conform to theIEC61000-4-30:2008standard:
• Powerfrequency• Magnitudeofthesupplyvoltage• Flicker• Supplyvoltagedipsandswells• Voltageinterruptions• Supplyvoltageunbalance• Voltageharmonics• Mains signaling voltage on the supply
voltage• Rapidvoltagechanges(RVC)• Measurementofunderdeviationandover
deviationparameters
MCC / MSB (MOTOR CONTROL CENTRE / MAIN SWITCH BOARD)
• 1x Moulded Case Circuit Breaker(MCCB) 150A TPN 415VAC 50Hz16kA,Motorised.
• 1xMicroprocessorbasedcombinedovercurrent and earth fault relay with digitaldisplay- SynchronismCheck- Bus/LineUndervoltage- Reverse Power- BreakerFailure- Overcurrent- PowerFactor- OverVoltage- Phase directional Overcurrent- Under/OverFrequency.
• 1xDigitalPowerMeter• Phaseindicatinglight(red,yellow,blue)• Setofcontrolfuse• Setofbusbar100ATP&N• Setofcurrenttransformer
9
Theloadmodulescompriseofsinglephaseandthree-phaseindustrialloads.
The loads are of resistive, capacitive, inductive andreactive(motor)types.Three3-phasegroupscanbevaried in small steps which together with the otherloads will cover load possibilities from 0-150% ofnominalpower.One motor with flywheel is enclosed to the loadmodule.
TheLoadModuleComprisesof;6 Step 3=phase resistive load bank controlled byincrease/decreasebySCADA.6 Step 3=phase capacitive load bank controlled byincrease/decreasebySCADA.6 Step 3=phase inductive load bank controlled byincrease/decreasebySCADA.
Resistive Load Bank
System shall be rated for 30kW, 3 phase,415VAC, 50Hz and consists of thefollowing:
A. Main Supply and Control Panel • 1xMCCB100A,TP&N50Hz,16kAc/w
shunttripandEarthLeakageRelay.• 1xAmmeter0~100Ac/wselectorswitch.• 1 x Voltmeter 0~500V c/w selector
switch.• SetofPhaseIndicatinglight(R,Y,B).• 1xsetofControlfuses.• 1 x set of Current Transformer for
measuringmeter.• 1xSetof100Abusbar.• 1xSheetmetalconsole.• 6xPushbuttons(green).• 6xPushbuttons(red).• 6xIndicatinglights.• Allwiringusingfiberglassinsulatedcable
as heat resistance
Load Modules
10
B. Load Bank Console • 6xResistiveloadbanksofcombinationof
1kW,2x2kW,5kW,10kWand20kW• 6 x Miniature Circuit Breaker 3P, 10kA
assorted amp rating according to theresistiveloadbank.
• 6xContactor.• 1xCoolingfanc/wthermostat&Miniature
CircuitBreakerSP.• 1xThermalswitch75°Ctopreventfrom
overheating.
Overall dimension (WxDxH) in mm:850x750x1800approx.
Inductive Load Bank
A. Main Supply and Control Panel • 1xMCCB100A,TP&N50Hz,50kAc/w
shunttripandEarthLeakageRelay.• 1xAmmeter0~100Ac/wselectorswitch.• 1 x Voltmeter 0~500V c/w selector
switch.• SetofPhaseIndicatinglight(R,Y,B).• 1xsetofControlfuses.• 1 x set of Current Transformer for
measuringmeter.• 1xSetof100Abusbar.• 1xSheetmetalconsole.• 6xPushbuttons(green).• 6xPushbuttons(red).• 6xIndicatinglights.
B. Load Bank Console • 6 x Inductive loadbanksof combination
of1kVAr,2x2kVAr,5kVAr,10kVArand20kVAr
• 6 x Miniature Circuit Breaker 3P, 10kAassorted amp rating according to theinductiveloadbank.
• 6xContactor.• 1xCoolingfanc/wthermostat&Miniature
CircuitBreakerSP.
Overall dimension (WxDxH) in mm:850x750x1800approx.
11
• Currenttransformerandtransducers- Splitcorecurrenttransformer- Output:5A
• Measurementneeded- Voltage- Current- Phase offset
ThefollowinganalysisshallconformtoIEC61000-4-30:2008standard:• Powerfrequency• Magnitudeofthesupplyvoltage• Flicker• Supplyvoltagedipsandswells• Voltageinterruptions• Supplyvoltageunbalance• Voltageharmonics• Mainssignalingvoltageonthesupplyvoltage• Rapidvoltagechanges(RVC)• Measurementofunderdeviationandoverdeviation
parameters
The following analysis functions conform to the EN50160:2007standard:• Powermeasurement• Energymeasurement• Aggregation(demand)• SmartPowerMetering• CanmeasureRealTimeVoltage/Current/KWatt/
PF/Frequency/VAR/VA/THD• Communication: Ethernet & any Bus
communication
MeasuringDetail
12
SCADASystemThe proposed DCS and SCADA system providessimulationofpowermanagementsolutionforfactory/facility operations. The system includes monitoringand control system to assist the students in the understanding of engineering and troubleshootingprocedures to reduce energy-related maintenancecost, avoid downtime and optimize equipmentutilization.
TheSCADAsystemiscomprisedofserverworkstations,sensors,RTUsandsignalhardware(inputandoutput),user interface (HMI), communication network andsoftware.ThesystemisconnectedtocomputerLANnetwork,providinginteroperabilitycapability.Refertosystemarchitectureblockdiagramonpreviouspageandsampleuser interfacegraphicson the followingpages.
The system tracks real-time power conditions,analyses power quality and reliability, and respondsquickly to alarms to avoid critical situations. Thesoftwarehelpstheusertostudytrendstorevealenergy
wasteorunusedcapacityaswellasverifyefficiencyimprovements and allocate costs to buildings orprocesses.
TheSCADAsoftwarefeaturesconsistof:
1. DataAcquisition2. RealTimeMonitoring3. Interoperability4. Reporting5. TrendsandAnalysis6. Power Quality Analysis7. Web Portal8. AlarmsandEvents9. Manual and Automated Control
The SCADA computer interfaces and collects datafromPowerMeter/Analyzer installedateachbranchof the 415V/240V power distribution points. Thepowermeterautomaticallymeasure,compensateandcorrect for transformer or line losses when meter is physicallyseparatedfromthepointofbillingorchangeofownership.
13
The system simultaneously captures voltage andcurrentchannelsforsub-cycledisturbancetransients,waveformrecording,transientcapture.Theuserwillbeable to determine the location of a disturbance more quicklyandaccuratelybydeterminingthedirectionofthedisturbancerelativetothepowermeter.Analysisresults are captured in the event log, along with atimestamp and confidence level indicating level ofcertainty.
Inadditiontopowermeterdata,theSCADAsoftwarealsoreceivestemperaturedatafromsensorsinstalledattheDEG,measuringoiltemperature.
Forfutureprovision,theSCADAsystemiscapableofprovidingmanualand/orautomatedcontrolofexternaldevices such as alarm light, buzzer, PLC and/orinterposing relays foroperating theVCBs locatedateachpowerbranchofthesub-station.
WorkstationAsDCSsimulation, theworkstation/servercomputeris the heart of SCADA system. The workstation
hardwareisanindustrialPC,equippedwithapplicableinterface cards for digital data communicationswithremotesensors,controllersandnetwork.
The workstation will be installed with the PowerAnalysis software that will be programmed andcustomized to specific SCADA system architectureanddisplaylayout.
Installedremotelyatthecontrolroom,theworkstationcomputerservesasuserinterface(HMI)forreal-timedatamonitoringandcontrol.
Power Meter interfaceThe Power Meter/Analyzer is connected at eachbranch of the power distribution points. This multi-channelpowermetermeasuresanddisplaysseveralparameters including voltage, current, power,frequency,transients,harmonicscontent,outagesforeachphaseline.
The SCADA computer will interface with the DigitalPower Meters using expansion module. It providesRS-485portcommunicationtotheSCADAcomputer.Sensors interface
The SCADA computer will interface with sensorsinstalledatDEG,panelsandloadbanks.Theinterfaceisenabledusingamulti-channelanaloginputmodulethat provides RS-485 port communication to theSCADAcomputer.
Output ControlThe SCADA command output control feature isavailable for future use. For future provision, theSCADA/HMI system can be programmed to controlexternaldevicessuchasalarmlight,buzzer,PLCand/orinterposingrelaysforoperatingtheVCBslocatedatthe sub-station.
14
SampleGraphic
SampleDetailReadingGraphic
15
SampleDetailReadingGraphic
SampleHistoricalSummary
16
SampleEnergy&DemandSummaryReport
17
GEN. SET A
Loadbank - Resistive
Loadbank - Reactive
Synronizing ControlPanel
MSB / MCCPanel
SCADA Junction Box
Workstation - Master
Workstation - Slave
Door
Door
GEN. SET B
Laboratory Layout
Head Office46, Jalan Saujana 2, Taman Industri Saujana, 09600 Lunas Kedah, MALAYSIATel: +604-484 7252 Fax: +604-484 9646 E-mail: [email protected]
KL Office2B, Jalan BRP 1/2, Bukit Rahman Putra, 47000 Sungai Buloh, SelangorTel: +603-61413400 Fax: +603-21784569 E-mail: [email protected]
www.topazit.com
TOPAZ INTEGRATED TECHNOLOGY SDN. BHD.
Power System Simulator:Power Management System for Students
Training and Experimental Lab