DEIF PPM Power Management System Operation and Troubleshooting

DEIF PPM Power Management System Operation and Troubleshooting Complete Guide

In ship electric propulsion systems, offshore platform power stations, and large emergency power stations, the DEIF PPM (Power Management) power management system serves as the core control unit, undertaking key tasks such as automatic parallel operation of multiple generator sets, load distribution, overload inquiry, and unloading of non critical loads. Its highly integrated HMI human-machine interface, flexible AOP-2 operation panel, and powerful Utility Software upper computer software provide operators with a complete toolchain from on-site monitoring to remote parameter tuning. However, faced with complex menu levels, numerous protection parameters, and potential communication failures, on-site engineers often need a detailed guide from a practical perspective. This article is based on the PPM operation manual (version 2.40.0 and above), which systematically sorts out human-computer interaction, alarm handling, parameter tuning, and typical fault mode analysis, helping operation and maintenance personnel quickly get started and calmly deal with various abnormalities.

Overview of Human Computer Interface System

The PPM system provides four complementary human-computer interaction pathways, covering on-site, remote, and debugging scenarios:

Display Unit: Connected to the main controller via a 9-pin Sub-D cable, it provides a 4-line x 20 character backlit LCD text display, equipped with 14 status LEDs and 6 navigation buttons (up, down, left, right, enter, return). Suitable for daily data reading, alarm confirmation, and simple parameter modification.

AOP-2 additional operation panel: connected to the main unit through an internal CAN bus, with a maximum distance of 500 meters. The panel provides 16 LED status lights and 8 function buttons for power station mode selection (semi-automatic/automatic/shaft generator/shore power/split bus), overload inquiry, safety parallel operation, and light testing. The meaning of LED light colors is clear: green indicates activation, yellow indicates status switching or request not confirmed, and red indicates serious alarm or lockout.

Utility Software upper computer software: Connected via USB or Modbus (RS-485/Ethernet), it provides graphical parameter browsing and modification, real-time trend recording, event log export, and firmware upgrade functions.

External alarm and monitoring system: Connected to third-party SCADA through RS-485 RTU or Ethernet TCP/IP Modbus, supporting DNP3.0 and MODBUS protocols.

Detailed explanation of display unit operation

1. Quick reading of LED status lights

The 14 LEDs on the display unit panel provide real-time status perception for operators:

Alarm (red): Flashing indicates the presence of an unconfirmed alarm; Constant illumination indicates that all alarms have been confirmed but there are still faults present.

Alarm inh. (yellow): An alarm has been suppressed or an external suppression input has been activated.

Cool. down (green): The cooling shutdown process is in progress.

Run (green): The generator is in operation.

Ready (green): The controller is ready to start.

Deload (yellow): Load shedding function activated, ready to disconnect.

On (green/yellow): Green indicates that the circuit breaker has been closed; Yellow indicates that the synchronization function is in progress.

PMS control (green): The unit is under power management control; Extinguishing is controlled locally.

Regulator on (green): Load distribution function activated.

1st Standby (green): This diesel engine is the next unit to be started.

Base load (green/yellow): Green indicates activation of the base load function; Yellow indicates that the base load has been selected but not activated.

Power (green): The auxiliary power supply has been connected.

Self check OK (green): Controller self-test passed.

1st Prior (green): This unit has the first startup priority.

2. Menu Structure and Navigation

The menu system is divided into two major systems: the "View" menu and the "Setup" menu

View menu (V1, V2, V3): used for daily operation monitoring. V1 can contain up to 15 user-defined windows (such as generator voltage, current, power, frequency, etc.), which can be manually switched by pressing the up and down keys; V2 and V3 automatically switch based on the unit status (start preparation → synchronization → load lifting → normal operation), without the need for manual intervention. In actual operation, the first line of V3 dynamically displays the current status text, such as "FIxed Frequency", "Gov LOAD SHARING", "RAMP DOWN", etc., which complement the specific measurement values displayed in the second and third lines.

Setup menu: divided into four submenus: PROT (protection), CTRL (control), I/O (input/output), SYST (system). Before entering, you need to enter a password (factory default 2000), and if there is no operation for 3 minutes, it will automatically exit and you need to log in again.

Engineering Tip: The display content in the View menu can be cropped through the "User View Configuration" function of Utility Software. It is recommended to place the most important parameters (such as power, current, frequency) in the first 5 windows for quick viewing.

Alarm and Event Management

1. Alarm list operation

When any protection function is triggered, the display unit will automatically jump to the alarm list. If you need to actively view, you can press the "INFO" key to enter directly. Each record in the alarm list contains:

Unacknowledged (UN ACK) or Confirmed (ACK) status

Total number of alarms and current serial number

Use the up and down keys to flip through pages, or select "FIRST"/"Last" to quickly locate

Once the alarm condition disappears and is confirmed, the record will be removed from the active alarm list but permanently stored in the event log (Log List).

2. Event log (Log List)

The log list can store up to 150 historical events, covering system power on, protection actions, circuit breaker opening and closing, parameter modification, etc. Press the "LOG" key to enter, and also support jumping by first/last event. This feature is crucial for post fault analysis - it is recommended that operators export log archives at least once a week.

3. Alarm processing logic

Typical alarm parameters include: Set point, Timer, Relay A/B, Enable, and Fail class. The fault level is divided into 8 levels (F1~F8), commonly mapped as: F1=Warning, F3=Block, F4=Trip CB, F6=Shutdown, etc. The specific meaning needs to refer to the Design Manual (DRH).

Power station mode management of AOP-2 operation panel

AOP-2 is a key component for implementing multi electromechanical station automation in PPM systems. Its 8 buttons and 16 LEDs support the following power station modes:

SEMI-AUTO (semi-automatic): The controller automatically performs synchronization, closing, and load distribution, but the start/stop of the unit needs to be manually initiated by the operator.

AUTO (fully automatic): Automatically start and stop the diesel engine according to the load of the busbar, achieving true "unmanned operation".

SHAFT (shaft generator mode): When the shaft generator supplies power to the busbar, PMS automatically limits the diesel engine start to avoid long-term parallel operation.

SHORE (shore power mode): When connected to shore power, PMS automatically disconnects the diesel engine and manages load transfer.

SPLIT (Split Busbar Mode): The busbar circuit breaker is disconnected, and both sides of the busbar operate independently, with each side managing its own connected unit.

In addition, the SECURED ON button can force an additional standby diesel engine to start (usually used to reserve margin before heavy load start), while the SECURED OFF button restores normal load dependent start stop logic. HC REQUESTED/CONNECTED LED is used to indicate the request and connection status of heavy loads (such as large compressors and thrusters), and to achieve sequential start-up of high-power equipment in conjunction with heavy load parameters (HC 1/2 maximum power, load type, confirmation type).

Practical operation of core functions of Utility Software

After the upper computer software is connected through USB or Modbus, the operator can obtain operation capabilities far beyond the local HMI:

1. Overview (Plant)

Real time display of single machine active power, current, phase angle, frequency, voltage, circuit breaker position, regulator status, and current alarm quantity. The symbols for analog instruments and circuit breakers can be customized, making it easy to quickly grasp the overall situation.

2. Historical alarms

List all previously activated alarms in a table format, including complete text, timestamp (accurate to milliseconds), active/inactive status, and confirmation status. Supporting sorting and filtering, it is the core tool for fault tracing.

3. Trending

Multiple measurement values (such as active power, frequency, current) can be selected simultaneously to draw the change curve, supporting scaling and translation. It is highly valuable for debugging PID parameters or analyzing load fluctuations.

4. Parameters

List all adjustable parameters by category (generator, busbar, NEL, synchronization, regulation, input/output, etc.). Click on any parameter (such as Reverse power) to bring up the settings window, where you can modify the settings, delay, and associated relays. After modification, it needs to be downloaded to take effect; On the contrary, 'upload' can read the current setting value into the PC backup.

5. Input/Output

Real time display of the status of all digital input/output, analog input/output, and VDO inputs. Support custom text labels (such as "emergency stop", "low oil pressure") for easy on-site recognition.

6. Logs

In addition to event logs, other diagnostic information within the controller can also be read. All logs can be saved as files for long-term archiving or sent to DEIF technical support.

Case Study of Key Protection Parameter Setting (Taking Generator Protection as an Example)

Here are several key points for setting commonly used protection parameters:

1. Reverse power (1001~1016)

Set value: usually set to -5%~-15% (negative values indicate power reversal).

Delay: 5-10 seconds to avoid brief reverse flow (such as during synchronization) and misoperation.

Fault level: generally set to F4 (trip) to prevent the motor from reversing after the prime mover stops.

2. Overcurrent (1031-1094)

Provide two modes: fixed time limit (1-4 segments) and inverse time limit (6-segment line). Taking inverse time as an example, six current time points can be set (such as 110%/5s, 120%/3.8s, 140%/2.5s... 200%/0.5s) to simulate a typical inverse time curve. Suitable for coordination with upstream protection to achieve selectivity.

3. Generator over/under voltage, over/under frequency

Overvoltage section 1 is usually set to 105%~110% with a delay of 5 seconds; undervoltage section 1 is set to 90%~95% with a delay of 5 seconds.

Over frequency segment 1 is set to 105% with a delay of 5 seconds; under frequency segment 1 is set to 95% with a delay of 5 seconds.

The fault level is usually F3 (shutdown) to avoid equipment damage.

4. Heavy Consumer (8201~8213)

Two sets of overloads can be defined, each requiring setting of maximum power, load type (fixed/variable), and confirmation type (steady state/pulse). When the request signal (HC REQUESTED) is activated and the current available power is sufficient, PPM will issue the HC CONNECTED signal, allowing overload input. If the power is insufficient, the controller will prioritize starting the standby unit.

Typical Failure Modes and Emergency Response (FMEA Summary)

Chapter 6 of the operation manual provides a detailed Failure Mode and Effects Analysis (FMEA), covering the following high-frequency fault scenarios:

Possible causes of the fault phenomenon, local impact, system level impact, and handling suggestions

The CAN interface is lost, communication lines are loose, or the board is faulty. The unit has lost PMS control, and all units are switched to local control. Speed/voltage regulation only relies on drooping to check the CAN bus connection and terminal resistance, and restart the controller

Loss of power supply 24V DC fault or complete failure of power supply line protection, the unit is uncontrollable and unusable. Check the fuse and power module, and it is recommended to configure dual redundant power supply

Circuit breaker closing failure, coil fault or failure to receive closing command, unable to connect to the grid. PMS sends out "next start" signal to check the closing circuit and pulse width setting (2024 tCB)

Abnormal feedback of circuit breaker position, auxiliary contact disconnected or short circuit position unknown, logical disorder. The unit does not participate in load dependent start stop inspection for auxiliary contacts and wiring terminals of 5a/56a

Generator shutdown failure operation signal does not disappear, fuel valve or shutdown coil is stuck, resulting in shutdown failure alarm. Check the stop relay (terminal 122) and shutdown circuit

Synchronization failure, slip, pressure difference or phase angle exceeding the limit, unable to close and timeout alarm, can be transferred to the next machine to check the synchronization parameters (dynamic fMAX, Δ U, tCB)

For each type of fault, the manual specifies the remedial actions automatically taken by the system (such as starting the next unit, switching to local mode, etc.), and operators should conduct regular fault simulation exercises to familiarize themselves with the operating procedures.

Daily maintenance and software upgrade suggestions

Regularly download event logs and trend data: It is recommended to export them once a month and save them in CSV format using the "Logs" window of Utility Software for analyzing the trend of unit performance degradation.

Check the communication between AOP-2 and the display unit: If it is found that the AOP-2 LED does not match the actual state, check whether the CAN bus shielding layer grounding is single ended reliably and whether the terminal resistance of 120 Ω is in place.

Firmware upgrade: Use the "Flash/upload a firmware" function of Utility Software to perform the upgrade. Before upgrading, be sure to back up all parameters. If there is parameter confusion after upgrading, you can perform "upload" to restore the backup.

Password management: The factory password is 2000, and it is recommended to change it immediately (channels 9116, 9117, and 9118 correspond to customer, service, and administrator permissions, respectively). Once forgotten, please contact DEIF technical support (provide hardware serial number) to reset.