Implementation of Digital Technology in a Standby Generator Upgrade Presented by: Steven Poyner and

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Implementation of Digital Technology in a
Standby Generator UpgradePresented bySteven
Poyner and David Calkin

• OVERVIEW
• BACKGROUND
• OBJECTIVES
• DESIGN
• SQA REQUIREMENTS
• VENDOR ENGAGEMENT
• INSTALLATION AND COMMISSIONING
• SUCCESSES/ CONCLUSIONS

Steven Poyner
David Calkin
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Implementation of Digital Technology in a Standby
Generator Upgrade
BACKGROUND

• Standby Generator Requirements and Performance
• Standby Generators (SGs) provide 4.16 KV Class
  III Power to supply essential loads on loss of
  Class IV Power.
• The SGs consist of 2 banks of 3 independent
  self-contained power plants.
• System has N1 redundancy.
• Capable of self powered start Black Start
  (without the aid of external auxiliary energy
  input) .
• Capable of accepting automatic block loads within
  2 minutes of the start signal.
• Control System schedules fuel, operates
  auxiliaries, provides speed control and
  alarm/trip protection.
• Start Reliability of 98. (0 Failures in 69
  attempts _at_ 75 confidence).

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Implementation of Digital Technology in a Standby
Generator Upgrade
BACKGROUND

• Pre Modification Reliability
• 20 yrs of Excellent Performance But.
• OPG System Health Indicator
• Obsolete Equipment
• Limited Spares
• Component Life
• Troubleshooting Obstacles
• Limited Diagnostics

Bathtub Curve
Replacement Recommended
Infant Mortality
Useful Life
Failure Rate
Rehab Recommended

• Pre Modification Rehabilitation
• Inverter Replaced
• Annunciator Replaced
• Relays Replaced
• Speed Switches Replaced

Rehab Buys Time
Time
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Implementation of Digital Technology in a Standby
Generator Upgrade
BACKGROUND

• Obsolete Parts
• HP Fuel Pump
• Fuel Valve
• Valve Actuator
• CDP Limiter
• Vibration racks
• Annunciator
• Speed Switches
• Analogue Governor

• Aging Parts
• Relays
• Timers
• Speed Switches
• Pen Recorders

Risk Cost Need Upgrade Scope
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Implementation of Digital Technology in a Standby
Generator Upgrade
DESIGN

• System
• Replacement Of Entire Control Panel
• PLC Based Technology
• Non Proprietary Technology
• Integrated Solution
• Networked Design
• Simple IEC 61131 PLC Language
• Human Factors Considerations

Gas Turbine
Power Turbine
LP Fuel System
Fuel Skid
Exciter
Generator
Gear Box
CT and PT SIGNALS
PT
GP
PT
Speed Signals
CDP
Field Transducer Signals
Field switch and transducer Signals
Speed Signals
Fuel Feedback
Exhaust Temp
AVR Generator Control
Hard Wired Trip
Machine Monitor Overspeed
Generator Protection Relays
Power Transducer
PLC
HMI
VSD
Main Control Panel
AC MCC
Remote I/O
Generator Control Panel
Enet Switch
600VAC Supply
Fuel Control
125VDC Supply
Data Logger
Hand Controls
Alarm Annunciator
VSD Control Panel
HMI
DC MCC
Remote Display
Generator Control Signals
MCR
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Implementation of Digital Technology in a Standby
Generator Upgrade
DESIGN

• Fuel System
• Replacement Of Entire Fuel System
• Variable Speed Pump Technology
• Non Proprietary Design
• Simple Hydraulic System
• Turn Down Ratio of 15/1

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Implementation of Digital Technology in a Standby
Generator Upgrade
DESIGN

• Fuel Control
• Black Start Capable
• Seamless transition from AC to DC
• Advanced Open Loop Control
• Non Proprietary Technology
• Integrated Solution

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Implementation of Digital Technology in a Standby
Generator Upgrade
DESIGN

• Governor
• Enhanced Light-Up Control
• Smooth Acceleration
• Implemented In PLC Logic
• Easily Understood
• Fault Tolerance Algorithms
• No Controller Set-Point Drift

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Implementation of Digital Technology in a Standby
Generator Upgrade

• System
• Easily Understood Interfaces
• 3 Network protocols

• PLC
• PLC integrates all devices
• Majority of functions are Firmware

Vendor PLC Logic
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Implementation of Digital Technology in a Standby
Generator Upgrade
SQA REQUIREMENTS

• Majority of Control Devices Category II
• - Devices used for operator display CAT III
• - Diagnostic tools such as the Data Logger CAT
  IV
• Excess of 40 COTS Devices Qualified
• - Devices Qualified based on OEM feedback and
  unit hours of operation
• - PLC Hardware has 100k unit yrs of operation
• - Additional testing required to qualify system
  Annunciator
• Vendor Software Limited to PLC logic
  configuration
• - PLC logic IEC 61131-3 Compliant Ladder Logic
• - PLC does not provide access to low level
  resources
• - PLC uses pre defined memory structures
• - Language reminiscent of relay logic
• - Sequential execution based on ladder sequence
• - User defined interrupts for critical tasks

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Implementation of Digital Technology in a Standby
Generator Upgrade

• Vendor Engagement
• Engaging specialized vendors for Nuclear Apps
  difficult
• None of the Bidders met CSA Nuclear QA standards
• Identified risks / gaps were
• - Corporate culture differences between OPG and
  the Vendor
• - Vendor unfamiliar with Quantity of Nuclear
  documentation
• - Vendor quality assurance (QA) rigor
• - Vendor comprehension of the requirements
• - Nuclear reqts driving Vendor off standard
  product offering
• - Vendor limited presence in North America
• OPG developed strategies to bridge the gaps
  shared resources
• Team approach adopted increased cooperation,
  communication
• OPG believes issues not vendor specific

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Implementation of Digital Technology in a Standby
Generator Upgrade

• Installation and Commissioning
• Decision made by OPG to start 1st installation
  Jun 2006 with 'approved as noted' Vendor
  drawings and manage revisions through EC process.
• SG Outage schedule very aggressive, need to
  upgrade SG's was acute. Install two in 1st year
  and three in 2nd year.
• Extensive planning, challenge reviews,
  installation plans, integration logics, field
  walkdowns
• Ran co-ordination out of site located trailer,
  updated and resolved issues through station plan
  of day process
• Installation went as planned (30 days), despite
  many legacy as found and discovery issues.

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Implementation of Digital Technology in a Standby
Generator Upgrade

• Installation and Commissioning Continued
• Commissioning started with the 150 loop checks,
  checking power supplies and connections
• 8MW rented loadbank was used to perform type
  islanded testing
• - Load acceptance and rejection blocks
• - Numerous black/white starts
• - AC/DC transfers
• - Loop tuning, hot-restarts, emergency and
  protection tests
• Commissioning took 45 days (planned 24)
• - Failed components
• - Configuration wiring issues
• - Loop tuning on CL III and loadbank
• - Set point changes and other logic changes
  through SQA process
• - CL III PT instability
• - VSD over-voltage trips
• Most issues attributed to 1st unit 'teething
  pains'
• Subsequent SG right on schedule, no major issues

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Implementation of Digital Technology in a Standby
Generator Upgrade

• Successes / Conclusions
• Performance of the modification is excellent,
  start reliability improved
• Hot restart capability, increased monitoring
  diagnostics, better load response,
  acceptance/reject
• Software field change process effectively managed
  the many changes

• Partnership and team work strategy with
  Commercial Vendor successful
• Upgrade flushed out latent legacy issues
• SG system health restored