Standard Aggregatebau KG / Germany

-Operation / Control & Protection Manual-

Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 01 / Page -1-

Section 1 - EDG / General Operation Process

The 1900KVA/4,16V/60Hz Diesel Generating Set for Metor II Expansion is designed for continous
emergency power supply in case of local power failure. The generating set operation & supervision
is splitted to following components

-1 no. local gauge panel located on genset baseframe

-1 no. generator control panel located in control room

-1 no. 4160V incoming feeder located in control room

-1 no. 4160V outgoing feeder located in control room

-1 no. air start compressor unit

-1 no. neutral grounding resistor

The generator control panel is equipped with a central digital control modul type Symap, which is the
major operational feature for the operator and includes all necessary devices for

-genset operation

-genset protection

-genset control

-power transfer

4 nos. operational generator functions are available via separate selector switch in the control panel

-Off genset out of service

-Manual push button start-stop operation of genset & breakers

-Automatic automatic start & load take over in case of mains failure
with automatic resynchronizing

-Mains Parallel immediate start up of genset to run for test purpose under load,
automatic synchronizing with mains and load take over
as per percentage programmed

In addition the engine can be started/stopped directly from genset mounted local gauge panel to check
operational conditions without any power transfer functions.
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -2-

Power transfer covers control & display of 4 nos . breakers as follows:

Generator Circuit Breaker (GS-1660)

-open/close function controlled by Symap acc. to operation modus
-breaker position displayed by Symap
-the generator circuit breaker can only be closed if the line breaker status contact provides a close
condition to the genset control panel

Line Breaker 52E (MS-1101)

-open/close function controlled by overall electric plant control system
-breaker position displayed by Symap
-if the line breaker will be opened by overall plant control the generator circuit breaker will automati
cally open as well

Tie Breaker 52ET(MS-1101)

-open/close function controlled by Symap acc. to operation modus
-breaker position displayed by Symap

Earth Breaker (GS-1660)

-open/close operation manually on the medium voltage incomer breaker panel
-breaker position displayed by Symap

Section 2 - Safety before Operation

Generally before any operation of the emergency generating set & equipment the operator has to en-
sure having studied the relating safety regulations within the overall documentation for the complete
equipment.

As a next step concerning safety, the operator should before local operation

-be sure about the location of the emergency push button

-be sure to not touch any hot genset components such as exhaust gas, cooling water, charge air
-to wear noise ear protection
-to check if emergency hand lamp is operatable
-to check escape routes out of powerroom

Finally the correct operational condition of the emergency power system has to be checked, beside the
detailed requirements within the overall documentation the following issues have to be again high-
lighted:

-check correct engine lube oil level via level stick

-check visually for any leakage in baseframe integrated lube oil drip pan
-check visually for any leakage at cooling water pipe connections between engine & radiator
-check visually the engine combustion airfilter colour for extensive filter contamination
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -3-

Section 3 - Control Panel / Operator Section

 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -4-

Section 4 – Manual Operation

1 – Set separate selector switch in panel front for generator operation modus to –Manual-
(Note Symap Man/Auto buttons are replaced and not active)

2 – Press green –Start- button

3 – Genset starts up to 1500rpm

4 – See Symap power indication display left showing 4160VAC and 60Hz

5 – Check bus tie voltage in minmic diagram on LCD display

6 – Press F4 button to activate breaker selection

7 – Select closed tie breaker (TB) by navigation arrows

 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -5-

8 – Press –0- button to open tie breaker and disconnect bus tie B

9 – Select open generator circuit breaker (CB) by navigation arrows (Menue Navigation)

10 - Press –I- button to close generator circuit breaker and transfer generator voltage to the bus tie

Note, there is an integrated interlocking safety device between tie breaker and circuit breaker.
The generator circuit breaker cannot be closed as long as the tie breaker is closed.
The tie breaker cannot be closed if the generator circuit breaker is closed.

To stop the generator in manual modus

1 – Select the generator circuit breaker (CB) by navigation arrows

2 – Press -0- button to open the generator circuit breaker and disconnect genset from bus tie

3 – Select tie breaker (TB) by navigation arrows

4 – Press –I- button to close the tie breaker and connect bus tie to mains

5 – Press –Stop- button to stop if the genset has run before without load, if the genset has been
operated before under load, allow the genset a suitable cooling down phase of approx. 5 minutes
before stopping the unit

6 – Set selector switch for generator operation modus back to standard operational condition in
–Automatic- position
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -6-

Section 5 – Automatic Operation

Automatic operation is the standard operation modus for the emergency diesel generating set which
should be selected generally before leaving the powerroom.

1 – Set separate selector switch in panel front for generator operation modus to –Automatic-

2 – The genset is now in automatic standby position, no further action by operator is necessary
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -7-

3 – In case of power failure

-the genset controller Symap will automatically recognize power failure

-the genset will start up automatically with 2 seconds delay once the 120VAC control voltage
from bus B is off or 20% voltage drop from nominal value.

The delay of 2 seconds will give time to provide power from bus A to bus B and only if both
bus A+B have power outage, the genset will start up.

-the bus tie breaker will automatically open

-the generator circuit breaker will automatically close

-the generator will provide power to the bus tie E for the time of blackout provided the
line breaker is closed by overall control system

In case the line breaker gets open, there is an automatic contact to the genset control panel
to open the generator circuit breaker simultaneously, to prevent any asynchronism in case the
generator circuit breaker will be closed and bus E is powered from bus b. Consequently the
generator circuit breaker can only be closed if the line breaker status contact provides a close
condition to the genset control panel

4 – In case power returns

-the genset controller Symap will automatically recognize power return on bus bar B

-the genset will automatically start synchronizing process

-the bus tie breaker will close automatically after positive synchronizing

-the genset is running parallel to mains

-the Symap controller will automatically shift the generator load back to mains

-the generator circuit breaker will open

-the genset will enter into stop phase

-after programmed 5 minutes cooling down time the generator will automatically shut down
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -8-

Section 6 – Mains Parallel Operation

Mains parallel operation allows to run the generator under load for test purpose in monthly intervals or
individually if requested to check if the unit is operatable.

Note Before Test Operation

Before mains parallel operation of the genset for test purpose the neutral grounding resistor must be
switched off manually. After test run under load, the neutral grounding resistor must be switched on
again.

It is not allowed to run the genset in parallel operation with grounding resistor switched on.
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -9-

1 – Power supply is provided by mains, the the line breaker and the bus tie breaker are closed.

2 - Set selector switch for generator operation modus to –Mains Parallel Operation-, no further action
required by operator for the moment

-the genset immediately starts up in test modus

-the genset will automatically start synchronizing process to bus B

-the generator circuit breaker will close automatically after positive synchronizing

-the genset is running parallel and will automatically take over load dependent of the load
signal set point programmed in the Symap controller, please refer to relating document where
values are shown

-the genset is running under load for the time requested, please refer to relating document
where values are shown

3 – Set selector switch for generator operation modus back to standard position –Automatic- to stop
load test run procedure

-the Symap controller will automatically shift the programmed load percentage from generator
back to mains

-the generator circuit breaker will open

-the genset will enter into stop phase

-after programmed 5 minutes cooling down time the generator will automatically shut down
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -10-

Section 7 – Local Gauge Panel

The local gauge panel is installed on the genset to show the operator the engine main parameters as

-engine speed
-cooling water temperature
-cooling water pressure
-exhaust gas temperature
-air intake restriction pressure airfilters
-charge air intake pressure manifold
-lube oil temperature
-lube oil pressure
-differential pressure lube oil filter

In addition the local gauge panel covers:

A key switch for local genset start/stop without load to check operational conditions
A genset emergency push button.
A key switch for start blocking of the genset under respect to service & maintenance works
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -11-

Section 8 - Protection

The emergency generator is fully protected via Symap controller against a wide range of mechanical
and electrical failures. The following list shall give the operator an overview of all programmed failure
& alarm conditions and the relating operational consequences:

SYMAP® Alarm- and operating indication

chan-
GEN. MAINS DIESEL
Alarm Alarm description ge
to bee-
C.B.OFF C.B.OFF STOP
No. MAN. per led control
immediate-
1 SHORT CIRCUIT ON BUS BAR Yes Yes NO ON Alarm+Trip+amber
ly
immediate-
2 SHORT CIRCUIT INSIDE GENERATOR Yes Yes NO ON Alarm+Trip+amber
ly
with coo-
3 GENERATOR OVERCURRENT 115% Yes Yes NO ON Alarm+Trip+amber
ling
with coo-
4 GENERATOR OVERCURRENT 130% Yes Yes NO ON Alarm+Trip+amber
ling
with coo-
5 GENERATOR REVERSE POWER Yes Yes NO ON Alarm+Trip+amber
ling
immediate-
6 GENERATOR OVERVOLTAGE Yes Yes NO ON Alarm+Trip+amber
ly
7 GENERATOR UNDERFREQUENCY NO NO NO NO ON Alarm+amber
8 GENERATOR UNDERVOLTAGE NO NO NO NO ON Alarm+amber
immediate-
9 GENERATOR OVERFREQUENCY Yes Yes NO ON Alarm+Trip+amber
ly
immediate-
10 GENERATOR DIFF PROTECTION Yes Yes NO ON Alarm+Trip+amber
ly
11 GENERATOR OVERLOAD NO NO NO NO ON Alarm+amber
12 STARTBLOCKING NO NO NO NO OFF Alarm+amber
immediate-
13 EMERGENCY STOP Yes Yes NO ON Alarm+Trip+amber
ly
14 LOAD TEST MAINS PARALLEL NO NO NO NO OFF green
15 LOAD TEST ISLAND OPERATION NO NO NO NO OFF green
16 CONTROL VOLT. 24 VDC TO HIGH NO NO NO NO ON Alarm+amber
17 CONTROL VOLT. 24 VDC TO LOW NO NO NO NO ON Alarm+amber
18 PREHEATING OPERATION NO NO NO NO OFF green
19 OIL PUMP OPERATION NO NO NO NO OFF green
20 OIL PUMP FAULT NO NO NO NO ON Alarm+amber
21 WATER PUMP FAULT NO NO NO NO ON Alarm+amber
22 PREHEATING FAULT NO NO NO NO ON Alarm+amber
23 COMPRESSOR 1 FAULT NO NO NO NO ON Alarm+amber
24 COMPRESSOR 2 FAULT NO NO NO NO ON Alarm+amber
immediate-
25 OVERENERGIZING Yes Yes NO ON Alarm+Trip+amber
ly
immediate-
26 UNDERENERGIZING Yes Yes NO ON Alarm+Trip+amber
ly
27 ENGINE START FROM PANEL NO NO NO NO OFF green
28 ENGINE START FROM ESD PLANT NO NO NO NO OFF green
29 COMPRESSOR 1 OPERATION NO NO NO NO OFF green
30 COMPRESSOR 2 OPERATION NO NO NO NO OFF green
31 STARTING AIR PRES TO LOW NO NO NO NO ON Alarm+amber
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -12-

32 AIR PRESSURE 1 TO LOW NO NO NO NO ON Alarm+amber

33 AIR PRESSURE 2 TO LOW NO NO NO NO ON Alarm+amber
34 COOLING WATER EXP TANK LEVEL LOW NO NO NO NO ON Alarm+amber
35 RADIATOR WATER LEVEL LOW NO NO NO NO ON Alarm+amber
36 EARTH C.B. RESISTOR OPEN NO NO NO NO OFF Alarm+amber
immediate-
37 STOP BUTTON NO Yes NO OFF green
ly
immediate-
38 STARTFAILURE Yes Yes NO ON Alarm+amber
ly
39 STOPFAILURE NO NO NO NO ON Alarm+amber
immediate-
40 SYNCHRONISATION FAULT Yes Yes NO ON Alarm+Trip+amber
ly
immediate-
41 DIESEL OVERSPEED Yes Yes NO ON Alarm+Trip+amber
ly
42 LINE SAFTY SWITCH FAULT NO NO NO NO ON Alarm+amber
43 PHASE SEQUENCE WRONG GENERATOR NO NO NO NO ON Alarm+amber
44 PHASE SEQUENCE WRONG BUS BAR NO NO NO NO ON Alarm+amber
45 PHASE SEQUENCE WRONG MAINS NO NO NO NO ON Alarm+amber
46 GEN WINDING 1 TEMPERATURE NO NO NO NO ON Alarm+amber
immediate-
47 GEN WINDING 1 TEMPERATURE Yes Yes NO ON Alarm+Trip+amber
ly
48 GEN WINDING 2 TEMPERATURE NO NO NO NO ON Alarm+amber
immediate-
49 GEN WINDING 2 TEMPERATURE Yes Yes NO ON Alarm+Trip+amber
ly
50 GEN WINDING 3 TEMPERATURE NO NO NO NO ON Alarm+amber
immediate-
51 GEN WINDING 3 TEMPERATURE Yes Yes NO ON Alarm+Trip+amber
ly
52 GEN BEARING DE TEMPERATURE NO NO NO NO ON Alarm+amber
immediate-
53 GEN BEARING DE TEMPERATURE Yes Yes NO ON Alarm+Trip+amber
ly
54 GEN BEARING NDE TEMPERATURE NO NO NO NO ON Alarm+amber
immediate-
55 GEN BEARING NDE TEMPERATURE Yes Yes NO ON Alarm+Trip+amber
ly
56 F.O.S. TANK LEVEL LOW NO NO NO NO ON Alarm+amber
57 F.O.S. TANK LEVEL HIGH NO NO NO NO ON Alarm+amber
58 EARTH C.B TIEBREAKER ON NO NO NO NO ON Alarm+amber
59 CONVERTER DC/DC 125V/24V FAULT NO NO NO NO ON Alarm+amber
immediate-
60 CONTROL OFF AND BLOCKED Yes Yes NO OFF Alarm+amber
ly
61 BLACK OUT NO NO NO NO OFF green
62 CHANGE OVER TO MAINS NO NO NO NO OFF green
63 TIE BREAKER TRIPPED NO NO NO NO ON Alarm+amber
64 CHANGE OVER FAILURE NO NO NO NO ON Alarm+amber
65 GENERATOR C.B. DON'T CLOSE NO NO NO NO ON Alarm+amber
66 GENERATOR C.B. DON'T OPEN NO NO NO NO ON Alarm+amber
67 LINE C.B. OPEN NO Yes NO NO ON Alarm+Trip+amber
immediate-
68 EARTH C.B. GENERATOR ON Yes Yes NO ON Alarm+Trip+amber
ly
69 COOLING WATER TEMP NO NO NO NO ON Alarm+amber
immediate-
70 COOLING WATER TEMP Yes Yes NO ON Alarm+Trip+amber
ly
71 LUBE OIL TEMP NO NO NO NO ON Alarm+amber
immediate-
72 LUBE OIL TEMP Yes Yes NO ON Alarm+Trip+amber
ly
73 LUBE OIL PRESSURE NO NO NO NO ON Alarm+amber
immediate-
74 LUBE OIL PRESSURE Yes Yes NO ON Alarm+Trip+amber
ly
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -13-

75 MAINS PROTECTION VECTOR SURGE NO NO Yes NO ON Alarm+amber

76 MAINS PROTECTION OVERFREQUENCY NO NO Yes NO ON Alarm+amber
77 MAINS PROTECTION UNDERFREQUENCY NO NO Yes NO ON Alarm+amber
78 MAINS PROTECTION OVERVOLTAGE NO NO Yes NO ON Alarm+amber
79 MAINS PROTECTION UNDERVOLTAGE NO NO Yes NO ON Alarm+amber

Symap displays the operational conditions via LED-lights

-green / ok

-orange / warning

-red (amber)/ automatic shut down

A relating text message concerning the operational conditions will be indicated next to the LED-light
within Symap LCD -display.

Once a failure occurs

-the alarm message must be acknowledged by the relating yellow button -Ack

-the problem must be fixed / repaired

-once the problem is fixed / repaired, the alarm message can be deleted from display by

pressing again yellow button –Ack-

In case of emergency press the red emergency push button in the center of the panel to immediately
stop the genset. To start again, the emergency push button must be released before, an additional red
light beside the emergency push button will further indicate if activated.

For maintenance works performed on the generator there is a –Start Blocking- safety key switch which
must be activated before any service on the unit to protect the service personal from unforeseen start
up of the genset. If the –Start Blocking- switch is activated, the emergency generator is set completely
off, no operational functions are available.

After service, the key switch must be unlocked to set the unit back into operational conditions.
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -14-

Section 9 – Symap F1-F3 Functions

The Symap controller displays beside the main page various further genset operation & programming
details covering

F1 – electrical measuring page showing the present electrical performance in every detail
F2 – alarms & history page showing any event up to 1000 nos.
F3 – control & processing page showing all parameter and program settings

The generator parameter settings & programming can be changed only via password access.

10 – Auxiliary Drive Section

The control panel is equipped with various control switches for start air compressor, prelubrication
pump, preheater, spaceheater & fuel filling pump.

During normal operation the genset is set to automatic position and all auxiliary drive switches should
be as well in -Automatic position-.

Beside the automatic position there is also a manual modus to run a.m. components by hand, for ser-
vice on the units the -0/Off- modus is available.

2 nos. analog instruments at the upper side of the control panel are showing the 24VDC control volt-
age & current, the control voltage should not be below 15VDC as the central genset controller Symap
otherwise will not operate and the emergency genset would be out of service.
 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -15-

11 – Medium Voltage Feeders

 Standard Aggregatebau KG / Germany
-Operation / Control & Protection Manual-
Emergency Diesel Generator 1900KVA/4,16KV/60Hz
Metor II / Venezuela
SAB-Reference 5281-E
Vendor # EDG-OCP-001 - Rev. 0 / Page -16-

The emergency generator power will be transferred to one dual 4,16KV medium voltage panel consist-
ing of one incomer & one outgoing feeder.

The incoming feeder is equipped with

-4,16V generator ciruit breaker motor driven

-3 nos. current transformers

-1 no. earthing switch hand operated

-Micom protection modul

-Janitza power indication per phase

-Busbar voltage check points per phase

-Mimic diagram breaker position

-Generator circuit breaker off switch

-Selector key switch remote & local operation generator circuit breaker
(local operation is disabled due to safety reasons)

-Disabled manual generator circuit breaker operation device (disabled due to safety reasons)

-Manual earthing switch operation device

Power transfer of the emergency generator will be effected via Symap controller within the generator
control panel either in automatic or manual modus as described before. The generator circuit breaker
can locally only be switched off, all further manual breaker operations are disabled due to safety rea-
sons.

It is not allowed to operate the generator circuit breaker from breaker panel.

For service of the medium voltage panels there is an integrated earthing switch which must be manu-
ally engaged / disengaged, the relating position of the earthing switch will be displayed on Symap
controller.

The medium voltage outgoing feeder covers the power connection terminals.

For any further more detailed information please refer to the relating component manuals within the
relating chapters of this documentation.