Power management Page 1 of 11

POWER MANAGEMENT

The power management is related to MINT application only. It is the process of

automatic starts and stops of gen-sets within the group, depending on current load,
state of the gen-sets and other conditions.

THE CONCEPT OF POWER MANAGEMENT

The power management is based on the load of the gensets, i.e. next gen-set will
start when the load of the group raises above certain level. A next gen-set will stop,
when the load drops down below a certain level. The proces of determining of starts
and stops is done in each controller, there is no "master" in the system. Each of the
controllers can be switched off without influencing the complete system (except the
situation when the respective gen-set will be not available..)

The load of the group is evaluated as so called reserve. The reserve is calculated as
difference between actual and nominal load of running gen-sets. The reserve can be
calculated as absoulute (in kW) or relative (in %). Use the setpoint
#Pwr mgmt mode to select the calculation method.

NOTE:
Power management based on relative reserves perfectly fits for applications, where
the load portions connected to the group at once are much lower than the gen-set
capacity. This mode helps to achieve maximal lifetime of the gen-sets, as they can be
operated within optimal load range. The maximal size of the load connected at
once depends on number of actually working gen-sets. The more gen-sets are
connected to the busbar the bigger load portion can be connected at once.

Power management based on absolute reserves can be successfuly used also for
cases where the load portions are similar to the gen-set capacity or even bigger. The
goal of the absolute reserve mode is that the system provides always the same
reserve power capacity independently on how many gen-sets are currently
running and this why this mode perfectly fits for industrial plants with large loads.

POWER MANAGEMENT BASICS

 The setpoint Pwr management enables and disables the gen-set to be active

within the power management of the group and make automatic load dependent
starts and stops. If the power management is disabled, the gen-set will run or
not depending only on the binary input Sys start/stop and the start and stop will
not depend on the load of the group.
 The binary input Sys start/stop activates and deactivates the gen-set. If the input
is not active, the gen-set will stop with delay #SysAMFstopDel after the input
has been deactivated and will not start again. It can be started in MAN mode
only. When the input is activated again, the delay #SysAMFstrtDel will start to
count down and after that the gen-set is activated and can start due to power
management.
NOTE:
The gen-set will take part of the power management (= will be active) only if the
controller is in AUT mode!

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NOTE:
The gen-set performs load and VAR sharing whenever it is connected to the busbar
i.e. it is independent on whether the controller is in AUT or MAN mode or whether the
power management is active or not.

RESERVES, MINIMAL RUNNING POWER

 The value 100*(1 - (Pact/Pnom)) [%] is called relative reserve. It is the

difference between actual relative load and 100%.
 The value Pnom - Pact [kW] (or Σ(Unom*Inom) - Sact [kVA], depending on
#Pwr mgmt mode) is called absolute reserve. It is the difference between actual
load of the group and nominal capacity of currently loaded gen-sets.

TotRunPact P = sum of actual load of all active gen-sets within the group, that are
Pact connected to the bus. In parallel to mains operation and baseload mode the baseload
level is taken to the equation instead of actual gensets load.

Pnom netPgnomPh = sum of nominal power of all gen-sets within the group, that are connected
to the bus.
Unom GenNomV = Gen-set nominal voltage.

Inom Nomin current = Gen-set nominal current.

Sact Sum of actual apparent load of all gen-sets within the group, that are connected to the
bus.

 If the current system reserve drops below the adjusted reserve for start, the
delay #NextStrt del will start to count down on the gen-sets, which have decided
to start. If the reserve remains under the limit for the whole countdown period,
the gen-set(s) will start.
 If the system reserve drops below 10 % (i.e. the system overload is
imminent), the delay #OverldNextDel will start to count down on the gen-sets,
which have decided to start (note that load reserve condition (given by
#LoadResStrt X  or #%LdResStrt X ) needs to be fulfilled as well). If the reserve
remains under the 10 % limit for the whole countdown period, the gen-set(s) will
start.
 If the system reserve rises over the adjusted reserve for stop, the delay
#NextStopDel will start to count down on the gen-sets, which have decided to
stop. If the reserve still remains over the limit, the gen-sets will stop.
 There are two sets of four pairs of setpoints for adjusting reserves for start and
stop. One set is for absolute reserves (in kW) and the other is for relative
reserves (in %). Which set is actually beeing used depends on the current
power management mode selected by the setpoint #Pwr mgmt mode. Normally
the pair #LoadResStrt 1, #LoadResStop 1 or #%LdResStrt 1, #%LdResStop 1 is
active. The binary inputs Load Reserve X the alternative pairs of reserves can
be selected.
 Using the function Minimal running power it is possible to limit the number of
running gensets so that the total nominal power of the loaded gen-sets will
never drop below this level even the reserve for stop is fulfilled. The function is
active when one of the inputs MinRun power 1, MinRun power 2 or
MinRun power 3 are is closed and the required value of the minimal nominal
power of running gensets is adjusted to the appropriate setpoint

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#MinRunPower 1, #MinRunPower 2 or #MinRunPower 3.

NOTE:
If the setpoint is adjusted to maximum, the function will force all gen-sets to run.

PRIORITIES

 The priority of the gen-set within the group is given by the setpoint Priority.
Lower number represents "higher" priority, i.e. a gen-set with lower number will
start before another one with higher number.
 The priority can be also adjusted by a set of binary inputs Priority sw A,
Priority sw B, Priority sw C and Priority sw D. If at least one of these inputs is
closed, the priority adjusted by the setpoint as mentioned above is overriden by
the priority given by the combination (binary code) of the Priority SW inputs.
NOTE:
The inputs are intended for adjusting the priority by a rotary switch.

 The force value function can be used to force priority 0 into the setpoint Priority.
Priority 0 is the "highest" one, which means the gen-set will be running all the
time while the power management is switched on.
 If more than one gen-set have the same priority, they will act as "one big" gen-
set.
 There are several methods of automatic optimalization of the priorities to
achieve specific behavior of the group such as equalizing engine hours of the
gen-sets or selection of optimal gen-sets to run according to their size and
current load demand. See the chapter Optimalization of priorities for more
details.

START AND STOP

 The controller will decide to start the gen-set in the moment, when the reserve
has dropped below the reserve for start and the gen-sets with higher priorities
(lower priority numbers), that are available for power management, do not have
enough capacity to get the reserve back over the start level or can not fulfil the
adjusted minimal running power.
 The controller will decide to stop the gen-set in the moment, when the reserve
has increased over the reserve for stop and the gen-sets with higher priorities
(lower priority numbers), that are available for power management, have enough
capacity to keep the reserve over the start level and also can fulfil the adjusted
minimal running power.

NOTE:
When evaluating the stop condition, the controller computes actual reserve without
taking in account the nominal power of self - i.e. it evaluates, how the reserve will be if
the respective gen-set stops.

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POWER MANAGEMENT WITH ABSOLUTE RESERVES

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POWER MANAGEMENT WITH RELATIVE RESERVES

REACTION TO ALARMS

 If a Shutdown or BOC alarm occurs, the gen-set will be taken out from the
power management and next gen-set will start if necessary.
 If a Slow stop alarm occurs, the gen-set will be taken out from the power
management, but the alarm will be suppressed for a definite time to give next
gen-set chance to start and connect to the bus to get the reserve back over the
start level. The alarm is suppressed until the reserve will get back over the start
level (can occur either due to next gen-set has connected to the bus or the load
has decreased..) or timeout given by setpoint #SlowStopDel has elapsed. The
alarm will not be suppressed, if there is no other available gen-set that can start.

OPTIMALIZATION OF PRIORITIES

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RUNNING HOURS EQUALIZATION

The running hours equalization (RHE) function is intended for keeping engine hours
of the specified gen-sets in the site equal or keep equal difference between them.
Keeping equal difference has the advantage that the gen-sets will reach it's regular
maintenance interval one by one and not all in the same time, which would happen
if the engine hours were kept equal without any difference.

 The function is activated by switching the setpoint #PriorityAutoSwap into the

RUN HOURS EQU position.
 At least one gen-set in the group must be set as the master for priority
optimalization (Priority ctrl = MASTER). It is possible to have more than one
master, the one with lowest CAN address will play the role of the master and if
it is switched off the next one will take the master role.
 To prevent too frequent starting and stopping of gen-sets, there must be
certain "deadband" in the running hours difference. This deadband is adjusted
by the setpoint #RunHrsMaxDiff.
 The setpoint RunHoursBase adjusts the "initial point" for the RHE function.
This setpoint is used to reflect the difference of engine hours in the moment
when the RHE function was activated as well as adjust cetrain required
difference which is to be kept.

EXAMPLE:
There are 3 gen-sets in the site. At the begining G1 has 5000 hrs, G2 has 10000
hrs, G3 has 12000 hrs. You want to adjust the system to keep G3 2000 hrs more
than G1 and G2 1000 hrs more than G1.

1. First we have to adjust the initial priorities to initialize the RHE function
properly. We adjust 3 for G1, 2 for G2 and 1 for G3.
2. The G1 has the lowest hrs value, so we take his 5000 hrs as the common
base and adjust it directly into the RunHoursBase of the G1 controller.
3. Next, we want the G2 to have 1000 hrs more than G1, so we adjust 5000 +
1000 = 6000 hrs into the same setpoint of G2 controller.
4. Finally, we want the G3 to have 2000 hrs more than G1, so we adjust 5000 +
2000 = 7000 hrs into the same setpoint of G3 controller.

As soon as we have the run hours bases adjusted, we adjust the #RunHrsMaxDiff at
one controller to let say 50 hrs. At the end we switch the RHE function on (setpoint
#PriorityAutoSwap). Both setpoints are synchronized, so it is consequently
automatically updated in all other controllers in the group via the CAN bus.

The system will then work following way:

 The G1 has actually 0 hrs above it's base, G2 has 4000 above it's base and
G3 has 5000 above it's base. In other words, G1 has 0 relative hours (RRH),
G2 has 4000 RRH and G3 has 5000 RRH.
 The RHE system will change the gen-set priorities in such a way, that the
relative hours of all gen-sets will be balanced with the tolerance adjusted by
#RunHrsMaxDiff. That means G1 gets the priority 1 (as it has the lowest RRH)
and G3 gets the priority 3 (as it has the highest RRH). G2 will remain at the
originally adjusted priority (i.e. 2).
 Always when the difference of RRH between a gen-set with lower priortity
number and other one with higher priority number rises above the tolerance,
the system swaps the priority numbers of these two gen-sets.

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NOTE:
The function does not work if the priorities are adjusted by binary inputs Priority SW
"X" or if there is an active force value function on the setpoint Priority.

GEN-SET SIZE OPTIMALIZATION

If there are gen-sets of different size in the site, it may be required always to run
such gen-sets that best fit to the actual load demand. The Load demand swap
function is intended for this purpose and can control up to 3 gen-sets.

NOTE:
This function works only in absolute power management mode.

 The function is activated by switching the setpoint #PriorityAutoSwap into the

LD DEMAND SWAP position.
 At least one gen-set in the group must be set as the master for priority
optimalization (Priority ctrl = MASTER). It is possible to have more than one
master, the one with lowest CAN address will play the role of the master and if
it is switched off the next one will take the master role.
 The gen-sets must have addresses 1, 2 and 3.
 There are four power bands, each of them has adjusted specific combination
of gensets that run within it. Power bands are adjusted by setpoints
#PwrBandContr1, #PwrBandContr2, #PwrBandContr3 and #PwrBandContr4.
The load levels of the power bands are defined by sum of nominal powers of
gen-sets that are adjusted to run in each particular power band, and the load
reserve for start.
 The combinations of gensets must be created so, that the total nominal power
of the Power band #1 < #2 < #3 < #4.
 If the load demand is above the power band #4 then all gensets are ordered to
run. In fact there is power band #5, which has fixedly selected all the gen-sets
to run.
 The currently active power band is given by the actual load demand. If the
load demand changes and gets out from the current power band, the
next/previous power band is activated with delay #PwrBnChngDlUp or
#PwrBnChngDlDn depending on the direction of the change.
 The gen-sets which are included in the current power band get priority 1, the
other get priority 32. The setpoint Priority is not influenced by this function (in
contrast to the RHE function, which overwrites the setpoints when it swaps the
priorities.

NOTE:
If the power band change delays are adjusted to higher values than #NextStrt del
and #OverldNextDel setpoints then it may occur, that also the gen-sets not
belonging to the current power band will start. This is normal and it prevents the
system from overloading.

EXAMPLE:
The site contains 3 gen-sets, G1 is 200kW, G2 is 500kW and G3 is 1000kW. The
reserve for start is adjusted to 50kW and for stop to 70kW.

We have then following available combinations of nominal power (ordered by size):

AVAILABLE POWER BANDS

GENSETS NOMINAL POWER [KW] POWER BAND [KW]

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G1 200 0 .. 150
G2 500 151 .. 450
G1+G2 700 451 .. 650
G3 1000 651 .. 950
G1+G3 1200 951 .. 1150
G2+G3 1500 1151 .. 1450
G1+G2+G3 1700 >1450

As we have only four power bands, we have to select the four most optimal
combinations from the table above and adjust them into the power band setpoints.
For this example it seems to be optimal power bands G1, G2, G3, G2+G3. The
"fixed" power band #5 with G1+G2+G3 will be active above the power band #4.

SELECTED POWER BANDS

POWER BAND GENSETS NOMINAL POWER [KW] POWER BAND RANGE [KW]
#PwrBandContr1 G1 200 0 .. 150
#PwrBandContr2 G2 500 151 .. 450
#PwrBandContr3 G3 1000 451 .. 950
#PwrBandContr4 G2+G3 1500 951 .. 1450
Fixed power band #5 G1+G2+G3 1700 >1450

LOCAL BASELOAD
The Local baseload function is intended for such cases, when it is preferable to run
all possible gen-sets at their nominal (or other predefined) load levels and keep only
one gen-set for equalizing the load changes.

 The function is enabled if the setpoint LocalBaseload is adjusted to any value

other than 0 (OFF).
 If the gen-set is running and the current situation allows it, the gen-set controls
it's load to the adjusted local baseload instead of taking proportional part from
the total load via the load sharing. The load changes are equalized by other
gen-sets that have local baseload off and/or by gen-sets with lower priority
(higher priority number). The power factor is then controller to the
#SysPwrFactor level.

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LOCAL BASELOAD PRINCIPLE

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LOGICAL GROUPS OF GEN-SETS

The physical group of the gen-sets (i.e. the site) can be separated into smaller logical
groups, which can work independently even if they are interconnected by the CAN2
bus. The logical groups are intended to reflect the real topology of the site when the
site is divided into smaller gen-set groups separated from each other by bus-tie
breakers. If the bus-tie breakers are closed the sub-groups have to work as one large
group and if the bus-tie breakers are open, the sub-groups have to work
independently.

 The group which the particular controller belongs to is adjusted by the setpoint
Control group. If there is only one group in the site, adjust the setpoint to 1
(=COMMON).
 The information which groups are currently linked together is beeing disributed
via the CAN. Each controller can provide information about one BTB breaker.
The breaker position is detected by the input GroupLink (i.e. this input is to be
connected to the breaker feedback).
 The two groups which are connected together by the BTB breaker mentioned
above are adjusted by setpoints GroupLinkLeft and GroupLinkRight.
NOTE:
The "group link" function is independent on the group, where the controller itself
belongs to. The controller can provide "group link" information about any two
groups.

 If the "group link" is opened the two groups act as two separated groups. If it is
closed the groups act as one large group.

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EXAMPLE:
The picture below shows an example of a site with 4 gen-sets separated by a BTB
breaker into two groups of 2. The BTB position is detected by the controllers 2 and 3.
The reason, why there are 2 controllers used for detection of the BTB position, is to
have a backup source of the group link information if the primary source (controller) is
switched off.

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