TECH LIBRARY 1 System and Overview ACGAL020S000001_A.pdf

System Overview & Safety Page 1 of 10 ACGAL020S000001_A.docx

Project: ACGAL020 Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

System Overview & Safety

ACGAL020S000001

Call Henry Inc.

Allison 501-KB

South Vandenberg Power Plant

Vandenberg AFB, CA USA

Revision Date Reason Approved A Created New

System Overview & Safety Page 2 of 10 ACGAL020S000001_A.docx

Customer: Call Henry Inc.

Printed 2017 / Printed in the USA

©2017, EthosEnergy Group LLC

PUBLISHED BY

EthosEnergy Group LLC

591 West 66th Street

Loveland, CO 80538

Contact information:

Toll Free: +1 (800) 437-9769 www.ethosenergygroup.com

The information contained herein is the property of EthosEnergy Group LLC and/or its subsidiaries. Any reproduction of it shall not be used for manufacture, production, procurement or any other use without the express written consent of EthosEnergy Group LLC. Use or reproduction for that which it is loaned is approved.

http://www.ethosenergygroup.com/

System Overview & Safety Page 3 of 10 ACGAL020S000001_A.docx

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

Table of Contents

SAFETY INSTRUCTIONS

SAFETY OVERVIEW

EQUIPMENT INSTALLATION SPECIFICATIONS

CABINET SAFETY

ELECTROSTATIC DISCHARGE AWARENESS

CONTROL OVERVIEW

REPLACEMENT CABINETs

SYSTEM DESIGN SPECIFICATION DOCUMENTS

REFERENCE DRAWINGS

Vendor DRAWINGS

REFERENCE SOFTWARE

System Overview & Safety Page 4 of 10 ACGAL020S000001_A.docx

Customer: Call Henry Inc.

SAFETY INSTRUCTIONS

A WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in damage to equipment or property.

A NOTE provides other helpful information that does not fall under the warning or caution categories.

SAFETY OVERVIEW

WARNING—DANGER OF DEATH OR PERSONAL INJURY

WARNING

This manual defines a controlling device and care must be taken to fully understand scope of equipment prior to installation and/or maintenance of this equipment.

Read this entire manual and all other related publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Follow all plant and safety instructions and precautions. Failure to follow instructions may result in personal injury and/or property damage.

Any unauthorized modifications or use of this equipment outside the specified mechanical, electrical, or other operating limits may cause personal injury and/or property damage, including damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or "negligence" within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage, and

(ii) invalidate product certifications or listings.

WARNING

The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover which could result in possible personal injury, loss of life, or property damage.

The overspeed shutdown device must function independently of the prime mover control system. Additional independent protections (i.e. fire system, over-temperature or over-pressure shutdowns) may also be needed for safety, as appropriate.

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

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Customer: Call Henry Inc.

CAUTION

The user must refer to all the instructions and warnings specified in the Operation Manual before using the equipment.

EQUIPMENT INSTALLATION SPECIFICATIONS

• Class I Equipment: Protective earthing of cabinet is required for safety.

• Supply Voltage fluctuation not to exceed +10% of the nominal supply voltage.

• Installation (Overvoltage) Category III for transient overvoltage.

• Electrical Ratings for each cabinet feed:

Control Cabinet:

o 24 VDC @ 20 Amps – Control Power

NOTE: A full system manual, consisting of circuit diagrams, system drawings, parts lists, sub-assemblies, component manuals, system design specifications, etc. is provided to aid in operating and servicing of the equipment.

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Customer: Call Henry Inc.

CABINET SAFETY

Preassembled control system cabinet inserts weighs approximately TBD kg.

The Control Assembly does not incorporate an accessible Disconnect Switch. The User is responsible for providing a suitable Disconnect Device for the incoming power supply feeds.

The Control Cabinet door should remain closed during normal operation. Internal servicing must be performed by Qualified and Authorized Personnel Only.

Customer supplied relay contact power must be fused at not more than 6A for each circuit if the circuit is capable of supplying more than 6A, including the short circuit current.

The Control Cabinet should be completely de-energized prior to removal or repair of any internal components.

System Overview & Safety Page 7 of 10 ACGAL020S000001_A.docx

Customer: Call Henry Inc.

ELECTROSTATIC DISCHARGE AWARENESS

All electronic equipment is sensitive to electrostatic charge, some components more than others. To protect these components from damage due to static discharge, special precautions should be followed to minimize or eliminate electrostatic discharges.

Follow these precautions when working with or near the control or when handling control system components:

1. Before performing maintenance on the electronic control, discharge the static electricity on your body to ground by touching and holding a grounded metal object (pipes, cabinets, equipment, etc.).

2. Avoid static electricity build-up on your body, including by not wearing clothing made of synthetic materials. Cotton or cotton-blend clothing is recommended to avoid build-up of static electrical charges.

3. Plastic, Vinyl, and Styrofoam materials (such as plastic or Styrofoam cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or folders, plastic bottles, and plastic ash trays) should be kept away from the control, the modules, and the work area as much as possible.

4. Do not remove the electronic modules from the control cabinet unless absolutely necessary. If a module must be removed from the control cabinet, follow these precautions:

• Do not touch any of the module electrical connector contacts.

• Do not touch the electrical conductors, the connectors, or the components with conductive devices or with your hands.

• When replacing a module, keep the new module in the antistatic protective bag until you are ready to install it. Immediately after removing the old module from the control cabinet, place it in the antistatic protective bag.

System Overview & Safety Page 8 of 10 ACGAL020S000001_A.docx

Customer: Call Henry Inc.

CONTROL OVERVIEW

This document describes system number ACGAL020 which was sold to Call Henry Inc. located at the South Vandenberg Power Plant at the Vandenberg AFB, CA USA. The control system replaces the Five

(5) Woodward based control systems for their Allison 501 Gas Turbine Generator sets and the associated GE Series Six sequencers.

TCS(Turbine Control System) electronic hardware is centered on a Rockwell Control Logix’s simplex controller with Local and Remote Chassis I/O and I/O devices connected on a redundant device level ring

(DLR).

EthosEnergy will leave the existing control cabinet in place and provide the new control hardware to install in the existing space.

Hardware for both the Turbine enclosure cabinet and the control room cabinet will be shipped as an assembled rack without a panel. These will be installed in the same place of the current GE Series 6 racks and the existing wiring will be terminated on the new modules.

For the governor cabinet, a replacement panel for the existing cabinet is provided. The only change is to replace the Woodward Atlas with the ControlLogix I/O rack. The existing Woodward Real Power Sensor and Airpax Overspeed switch will be reused. Current LVDT signal conditioners will be provided as new and the CIT temperature converter will be eliminated (since the Rockwell module can accept the mV signal). Since the sequence and governor systems are integrated, some of the hardwired interface signals are no longer required.

REPLACEMENT PANELS AND RACKS

Turbine Control System includes the following hardware:

• Allen-Bradley ControlLogix System including:

o Local and Remote Chassis o Processor o I/O Modules o Communications Modules (Ethernet) o Speed Input Module o Vibration Input Module

• Two new HMI Computers (exclusive of monitors):

o FactoryTalk View Software and Runtime Licenses

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Customer: Call Henry Inc.

SYSTEM DESIGN SPECIFICATION DOCUMENTS

The following documents include information necessary to operate and troubleshoot the turbine generator control system and related equipment.

DESCRIPTION REFERENCE DOCUMENT SOURCE

System Overview & Safety ACGAL020S000001 EthosEnergy

System Design Specification ACGAL020S000002 EthosEnergy

System HMI Interface Specification ACGAL020S000003 EthosEnergy

REFERENCE DRAWINGS

The following drawings include information required to install, test, operate and troubleshoot the turbine generator control system and related equipment.

DESCRIPTION DRAWING TYPE DRAWING NUMBER

Control System Schematics ACGAL020W000000

Control System Panel Assembly ACGAL020E000000

VENDOR DRAWINGS

The following vendor drawings include information required to install, test, operate and troubleshoot the AVR system and related equipment.

DESCRIPTION DRAWING TYPE DRAWING NUMBER

System Overview & Safety Page 10 of 10 ACGAL020S000001_A.docx

Customer: Call Henry Inc.

Site: South Vandenberg Power Plant Location: Vandenberg AFB, CA USA

REFERENCE SOFTWARE

The following list of software includes the source code and application tools necessary to install, test, operate and troubleshoot the turbine generator control system and related equipment.

DESCRIPTION REFERENCE DOCUMENT /

VERSION

SOURCE

Application Software

RSLogix 5000 Unit Program File ACGAL020S050000 EthosEnergy

FactoryTalk HMI Program File ACGAL020S040000 EthosEnergy

Software Development/Maintenance

RSLogix 5000 Ver 24.01 Rockwell

FactoryTalk Ver 8.00.00 (CPR 9 SR 7) Rockwell

SIMCFG 0.3 EthosEnergy