CASE STUDY: CENTERPOINT ENERGY

Application Sheet AS7407

Generator Control Systems for CenterPoint Energy Gas Compression Stations

TYPE OF PLANT New-build power generation plants for gas compression stations. Plants currently run in isolated, island-mode operation with provisions added in the system design for future utility parallel operation. PRIME MOVERS Plant 1: (3x) Caterpillar G3516A Gas Engine-Generators Plant 2: (3x) Caterpillar G399 Gas Engine-Generators Plant 3: (3x) Caterpillar G3516A Gas Engine-Generators PROJECT OVERVIEW Plant 4: (3x) Caterpillar G3516A Gas Engine-Generators CONTROL TECHNOLOGIES Woodward EGCP-3 LS Generator Control Package for synchronizing, load-sharing, monitoring, and protection. Woodward ProAct ISC Actuator with integrated speed control functionality. Basler DECS-100 and DECS-200 Automatic Voltage Regulators Woodward DSS Digital Speed Switch CenterPoint Energy has built four new natural gas processing stations within a two-year time span. Each station consists of eight or more gas compression units, driven by Caterpillar G3516A+ engines, and its own power generation plant; each plant with three Caterpillar G3516A engines with a combined output of 2.4 MW. These stations were constructed in remote locations and currently only one facility has access to local utility power. The power generation plant for each station supplies full-time power to the facility in island mode operation. Future plans call for utility service to be supplied to these stations, so provisions have been added to the system designs allowing utility parallel operation to be added once utility service is in place. Two of the plants are connected via a bus-tie breaker that allows six generators to be paralleled together. This breaker is controlled via a Woodward SPM-D synchronizer. In addition, the Woodward EGCP-3 generator control packages are interfaced to an Allen Bradley PLC and HMI via ModBus protocol in a readonly configuration for display of vital system information in the operator control room.

CASE STUDY: CENTERPOINT ENERGY

PLANT 1 COMMISSIONING The equipment for the first power generation plant was supplied by an outside company prior to the involvement of GCS in the project. When it came time for startup, GCS was contracted to perform commissioning on the Woodward equipment since the original design firm was unfamiliar with the operation of these controls. When technicians arrived, they saw more work than was originally anticipated due to the inadequate installation of the equipment (example shown in Figure 1). GCS worked through these issues rewiring and cleaning up the installation, commissioning the equipment, and producing a system that performed above the customers expectations. Based on the professional job exhibited, GCS was awarded with the opportunity to provide the power generation equipment for the upcoming plants from start to finish. This included design of the control cabinets all the way through to final commissioning.

Figure 1: Original Installation

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CASE STUDY: CENTERPOINT ENERGY

CONTROL TECHNOLOGIES Now responsible for specification of the power generation controls, GCS took the opportunity to review the application and utilize control equipment that was better suited for the engines than had been previously specified by the original design firm. GCS leveraged years of experience our engineers have specifically with these types of Caterpillar G3500 gas engines to develop a system that represents the best combination of factory equipment design and more modern control technology. The Woodward EGCP-3 generator control package was utilized as the basis for plant control including synchronizing, loadsharing and monitoring. The EGCP-3 LS provides complete control over each individual generator, while the EGCP-3 MC was provided to control transfers to and from the utility feeds once they are supplied to the compression stations. BASLER VOLTAGE REGULATORS Plant 1 originally utilized Caterpillar VR3 voltage regulators for all three G3516A engines. During the commissioning of this first plant, GCS experienced insufficient voltage stability due to the inherent issues associated with outdated control technology. The VR3 regulators were unstable to the point of causing problems when synchronizing a third generator to the plant load bus.

Once GCS had project design control, the designs were changed replacing the Caterpillar VR3 with Basler DECS-100 and DECS-200 regulators. The DECS-100 units were used on the G399 generators while the DECS200 units were used on the G3516A generators. Woodward DSS Digital Speed Switches were added to the system to activate and deactivate the voltage regulator at the appropriate engine speeds. The Basler voltage regulators considerably improved system performance and stability over what was seen at Plant 1. With successful commissioning at subsequent plants and at the recommendation of GCS, CenterPoint Energy agreed to replace the VR3 regulators supplied by the original design firm with DECS-200 units at Plant 1. WOODWARD PROACT ISC The engine-generator packages used at these plants were refurbished units as opposed to new factory packages from Caterpillar. As such, the engines did not include a speed control as supplied to CenterPoint Energy. In the redesign for subsequent plants, GCS elected to use Woodwards ProAct ISC actuator with integrated speed control. This control was utilized for many reasons. First, the ProAct ISC replaces equipment normally found on this style of Caterpillar engine with a more reliable design. The ProAct ISC is an actuator that includes an integral speed control replacing both the Woodward EG3P hydraulic actuator mounted on the engine along with the commonly found Woodward 2301A or 2301D controls.

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CASE STUDY: CENTERPOINT ENERGY

Figure 2: Linkage Before This upgrades the engines to an all-electric actuator that is not dependent on a clean engine oil supply for proper operation. In addition, the original engine design from Caterpillar includes an inconvenient linkage design between the actuator and throttle body that has multiple pivot points and long linkage rods. Each joint introduces another opportunity for shaft play which results in unstable control. The ProAct ISC is mounted near the throttle reducing the linkage to a few inches in length translating to far better engine control. Finally, this actuator configuration is designed to be consistent with the Caterpillar factory design found on the G3500A+ gas compression engines used at these stations.

Figure 3: Linkage Before The mounting shown in Figure 4 is designed in-house by experienced GCS mechanical engineers and is available as a standard kit for the Caterpillar G3500 series engines. BUS TIE SYNCHRONIZATION During commissioning of Plant 2, GCS was informed of a bus tie breaker in the system that had not been specified in the original plant specifications and was asked to design and implement a synchronization system on-site and on-the-fly. GCS responded with application engineers working closely with on-site field service engineers to produce the necessary engineering drawings and supply the hardware to the plant for installation and commissioning. This represents a unique challenge that shows the commitment and service GCS offers. SUMMARY GCS was contracted by CenterPoint Energy due to the knowledge and extensive experience with Woodward controls and Caterpillar engines demonstrated by our engineering and service teams. GCS service and application engineers were able to identify problems with the system supplied by the original design firm and apply the appropriate changes to produce power generating systems that exceeded the expectations of CenterPoint Energy. GCS exhibited the knowledge and professionalism that is standard in the projects we undertake and our support of these systems continues into the future with the round-the-clock availability of our service team.

Figure 4: Linkage After

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CASE STUDY: CENTERPOINT ENERGY

ABOUT CENTERPOINT ENERGY The CenterPoint Energy distribution network is composed of an electric transmission and distribution utility serving the Houston metropolitan area, local natural gas distribution businesses in six states, a competitive natural gas sales and service business serving customers in the eastern half of the U.S., interstate pipeline operations with two natural gas pipelines in the mid-continent region, and a field service business with natural gas gathering operations, also in the mid-continent region. CenterPoint Energy serves more than 5 million metered customers with over 11,000 served through the natural gas sales and service business in the eastern United States.

Established in 1983, Motor-Services Hugo Stamp, Inc. has continuously provided turnkey services for the maritime and stationary power industry. MSHS specializes in the repair, maintenance, and testing of diesel engines, turbochargers, and water jet propulsion systems. Learn more at MSHS.COM. Corporate Office 3101 SW 3rd Avenue Fort Lauderdale, FL 33315 Phone: 954-462-7404 Toll Free: 877-659-6328 Fax: 954-761-8768 Gulf Office 2022 Tamvest Court Mandeville, LA 70448 Phone: 985-626-8707 Toll Free: 888-GCS-GULF Fax: 985-626-8732

As a subsidiary to MSHS, GCS offers comprehensive control system support, from engine and turbine systems integration to turnkey project management for a broad range of marine, power generation and industrial projects. GCS engineers have experience with dual-fuel engines in both OEM and aftermarket applications. Learn more at GOVCONSYS.COM.