POWER June 2011 - 21

JOIN THE REVOLUTION
and the labor to install the cables also increases-a situation
to be avoided.
Package Wiring Upgraded
Each of the eight FT4 engines has two thermocouple compensation
harnesses. To obtain better engine temperature
reading and tighter control of the fuel governor, these harnesses
were replaced and new cable runs were installed. The
thermocouple wiring harnesses required special cables custom
manufactured by a third-party supplier based on HPI's
specifications. As a result of this and other improvements,
the engine control system can operate closer to its maximum
operating parameters, achieving an overall increase in power
output and unit efficiency.
Previously, the fire and gas alarms were a standalone system
producing only an audible alarm. The operator was responsible
for recognizing and responding to the alarm and
manually tripping the engine(s) if required. New fire and
gas monitors were installed and integrated with the turbine
control system so that alarms are clearly visible on the main
control panel. The new fire and gas alarms now indicate
exactly where in the engine and generator compartments an
alarm condition has occurred and will automatically trip the
engine(s) when needed.
The old seismic vibration and speed probes were replaced
with a new Bentley Nevada (BN) 3500 series system, along
with its associated cabling. This enhancement of the vibration
system gives operators greater visibility of the turbine
driveline's real-time operating conditions. The entire
BN 3500 was integrated with the PLC system, and data is
presented graphically on a dedicated vibration page on the
main control panel. Finally, the BN keyphasor module was
fitted on the shaft of the generator to measure vibration of
the gear box shaft.
Challenges Faced
Due to this particular utility's security policies, all project documentation
was transported manually rather than sent electronically.
A dedicated hard drive, in a sealed workspace, was set up
at HPI to support the project. Access to project information was
limited to those individuals on the project who were approved
to view project documentation. The HPI team was also required
to have security clearances, an additional logistical constraint
on the project team.
The evolving design of the cabling system during construction
meant that the cable schedules were frequently updated,
necessitating additional material purchases. The HPI team was
able to mobilize additional cable installers to ensure that the
project remained on schedule.
Key Results
The project was completed in May 2010 after about 10
months total site time. HPI received an " Excellent " rating
on all phases of the project from the customer. There were
two important reasons for the project's success. One was
effective project management and good communications between
the owner and contractor. Another was the fact that
an integrated project team composed of controls engineers,
installation technicians, and electricians-led by an experienced
project manager-provided the right mix for handling
a project with a dynamic scope of work. ■
-Contributed by Thaddeus Berry (tberry@hpi-llc.com), business
development manager, HPI.
June 2011 | POWER
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POWER June 2011

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