Sandbox

Goldrush Generator Design

Project workspace for integrating two CAT 3516C 2500 kW generators into the existing 13.8 kV Goldrush switchgear, with SEL generator protection, RTAC-based supervisory logic, HMI development, communications mapping, UFLS, commissioning, and project tracking.

2 x 2500 kWCAT 3516C gensets
13.8 kVGenerator bus voltage
SEL-3555Generator RTAC core
7 PhasesExecution plan
Architecture

Dedicated Generator RTAC

SEL-3555 acts as the supervisory automation platform for mode logic, HMI, UFLS, alarms, and upstream station integration to the existing SEL-3530.

Protection

Generator Relays

Two SEL-700G relays provide generator protection and final synchronism-check authority for generator breaker closing.

Field Verify

Main/Tie Sync Inputs

Execution plan assumes SEL-751 main and tie relays have usable VSYNC inputs and PT reference availability. This needs early validation.

Design Thread

  • Normal utility operation with generators in standby.
  • Generator synchronization to a live utility-supported bus.
  • Utility-parallel and generator-parallel operating modes.
  • Island operation with staged underfrequency load shedding.
  • Controlled return-to-utility using main relay synchronizing capability.
  • Tie transfer and synchronizing logic where required by the station transfer philosophy.
  • Hardwired protection/control retained for critical trip, close, and lockout paths.
  • Communications used for supervisory visibility, alarms, events, and noncritical automation data.

Reference Files

Goldrush Switchgear One-LineExisting 115 kV / 13.8 kV switchgear, bus, tie, feeder, PT, CT, generator breaker, and relay context.
Open PDF
Execution PlanSeven-phase plan from basis of design through closeout and turnover.
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Communications NarrativeSEL-3555-centered network, ECS-200 Modbus TCP, SEL relay communications, DNP3 to existing RTAC, SEL-2407 time sync.
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Control Narrative SummaryNormal, sync, parallel, island, UFLS, return-to-utility, and tie transfer modes.
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Generator Breaker Close ResponsibilityECS-200 close initiation, SEL-700G hardwired sync-check/permissive in series, RTAC sequence coordination, breaker feedback, and blocked-close handling.
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SEL-700G Recommended Part NumberQuote-ready SEL-700G1+ ordering basis for the Goldrush generator protection relays.
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RTAC UFLS Control SchemeNon-sub-cycle staged load shedding philosophy, RTAC arming logic, feeder trip stages, restore rules, tags, HMI requirements, and commissioning notes.
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Return-to-Utility Closed Transition PhilosophyPreferred restoration main, required tie breaker path, SEL sync permissives, RTAC sequence states, open-transition fallback, and HMI requirements.
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ECS-200 Point-to-Point Wiring UpdateHardwired RTAC, SEL-700G, breaker, and ECS-200 interface matrix updated from CAT M0170677-04 customer wiring sheets.
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Generator BOMCAT retrofit, SEL relays/RTAC, panel integration, control power, wiring, communications, sync reference material.
Download
End-of-October Project ChecklistSource workbook for the project tracking checklist, status legend, and RTAC loop philosophy notes.
Download

Document Gaps To Add

  • Basis of design with agreed control authority and operating modes.
  • I/O list and termination plan.
  • Communications point map and IP addressing.
  • UFLS feeder priority matrix.
  • Commissioning checklist and test forms.
  • As-built settings package and HMI screen list.
Goldrush HMI Screen Deck Station One-Line Overview
RTAC Online SEL Comms Good ECS Modbus Good Draft Layout

Goldrush Substation Simplified One-Line

Operator cover screen for station navigation. Click an equipment block to open relay, transformer, feeder, or generator-controller detail.

Detail screens should eventually bind each block to RTAC tags, alarm status, quality, timestamp, and command permissions.

Main / Tie Breaker Relay Summary

Station RTAC LinkDNP3 / mapped status to existing SEL-3530
Good

Typical Main / Tie HMI Points

BRK_STATUSOpen / Closed / Tripped / Unknown
SYNC_PERMISSIVEVoltage, slip, angle, and source checks
LOCKOUT_STATUS86, protection trip, or remote block active
CONTROL_MODELocal / Remote / Test / Disabled
RELAY_HEALTHComms, self-test, alarm, time quality
EVENTSTrip target, SER, latest close/trip command

Feeder Breaker Relay Summary

UFLS Stage 1priority feeder trip group
Armed
UFLS Stage 2 / 3deeper island recovery groups
Armed

Typical Feeder HMI Points

FEEDER_BRK_STATUSOpen / Closed / Tripped
FEEDER_KWReal load for UFLS decisions
UFLS_STAGEAssigned stage and current armed state
TRIP_TARGETOvercurrent, ground, manual, UFLS, lockout
RESTORE_READYVoltage, frequency, and operator permission
RELAY_COMMSQuality, stale data, and time sync
Substation Transformer Annunciator Normal - No Active Trips

Simple operator alarm screen for the two 115 / 13.8 kV transformer source paths. Alarm colors show normal, warning, and trip/lockout states.

XFMR-1 StatusEnergizedMain 200 source path
XFMR-2 StatusEnergizedMain 300 source path
Active Alarms0unacknowledged: 0
Last EventNoneall points normal
XFMR-1 Oil Temp68 Calarm 90 C / trip 105 C
XFMR-1 Winding Temp74 Calarm 110 C / trip 130 C
XFMR-2 Oil Temp66 Calarm 90 C / trip 105 C
XFMR-2 Winding Temp72 Calarm 110 C / trip 130 C
XFMR-1Sudden Pressure NormalNo rapid tank pressure change input active.
XFMR-1Oil Level NormalMain tank level and conservator alarm input normal.
XFMR-1Fan Auto AvailableCooling fans in auto. Alarm if fan fail or hand/off mode is detected.
XFMR-186T Lockout ResetTransformer lockout relay reset and available.
XFMR-2Sudden Pressure NormalNo rapid tank pressure change input active.
XFMR-2Oil Level NormalMain tank level and conservator alarm input normal.
XFMR-2Fan Auto AvailableCooling fans in auto. Alarm if fan fail or hand/off mode is detected.
Trip Tile Example86T / Differential TripRed tile reserved for active transformer trip or lockout condition.

Recommended point set: oil temperature alarm/trip, winding temperature alarm/trip, sudden pressure, low oil level, fan fail, fan auto/hand status, pressure relief, transformer lockout 86T, differential trip, neutral ground fault if available, source voltage healthy, relay comms quality, and last-event timestamp.

UFLS Mode Armed - Island Standby

RTAC supervises staged feeder shedding after island mode is confirmed. Fast machine control stays in CAT controls; feeder trip execution is through SEL relay / hardwired breaker paths.

BUS_FREQ_HZ60.00Hz island bus
GEN_TOTAL_LOAD0kW online
SPIN_RESERVE--kW available
ACTIVE_STAGE0no shed active
Stage 1 59.5 Hz for 0.5s Trip lowest-priority noncritical feeders on sustained frequency decay or verified generator overload. Confirm breaker open and kW relief.
Stage 2 59.2 Hz for 0.5s Trip second-priority feeders if Stage 1 does not stabilize frequency or generator loading before the escalation timer expires.
Stage 3 58.8 Hz for 0.3s Aggressive shed for critical frequency decay or overload to preserve generator stability and keep essential loads energized.
Restore Logic Operator Confirmed Restore only after stable timer, load margin, frequency recovery, and no active generator alarm.

Feeder 1

Stage 1
Load
-- kW
Status
Closed
Trip Path
Ready

Feeder 2

Stage 1
Load
-- kW
Status
Closed
Trip Path
Ready

Feeder 3

Stage 2
Load
-- kW
Status
Closed
Trip Path
Ready

Feeder 4

Stage 2
Load
-- kW
Status
Closed
Trip Path
Ready

Feeder 5

Standby
Load
-- kW
Status
Closed
Trip Path
Ready

Feeder 6

Stage 3
Load
-- kW
Status
Closed
Trip Path
Ready

RTAC Decision Tags

UFLS_ISLAND_CONFIRMEDFalse
UFLS_ARMEDTrue
UFLS_STAGE_REQUESTNone
UFLS_TOTAL_KW_SHED0 kW
UFLS_ESCALATION_TIMERReset
UFLS_LOAD_SHED_FAILEDFalse

Restore And Blocked Reasons

RESTORE_READYFalse until stable frequency, load margin, and generator alarms are clear.
RESTORE_MODEOperator-confirmed feeder restore, one feeder/stage at a time.
BLOCK_REASONNo island confirmed / insufficient reserve / generator alarm / breaker feedback mismatch.
VERIFY_AFTER_TRIPConfirm breaker open and actual kW relief before the next stage decision.

13.8 kV One-Line Context

MAIN 200
Closed
TIE
Open
MAIN 300
Closed
G12500 kW
GCB
Open
Sync
Waiting
UFLS
Armed

Electrical Readings

GEN1_KW0kW
GEN1_KVAR0kVAR
GEN1_PF1.00power factor
GEN1_FREQ_HZ60.00Hz
GEN1_V_LL_AVG13.80kV L-L
GEN1_I_AVG0A

Engine Package Readings

GEN1_ENGINE_RPM0rpm
GEN1_OIL_PRESSURE--psi
GEN1_COOLANT_TEMP--deg F
GEN1_BATTERY_VDC24.6VDC
GEN1_FUEL_LEVEL--%
GEN1_RUNTIME_HOURS--hours

Status, Mode, and Alarms

GEN1_ECS_MODE_CODEAuto
GEN1_RUNNINGStopped
GEN1_AVAILABLEReady
GEN1_REMOTE_ENABLEDEnabled
GEN1_COMMON_ALARMNormal
GEN1_COMMON_SHUTDOWNClear
GEN1_WARNING_CODENone
GEN1_SHUTDOWN_CODENone

RTAC Virtual Outputs From Modbus Reads

GEN1_READY_TO_STARTTrue
GEN1_ECS_COMMS_FAILFalse
GEN1_BLOCK_REASONNo active block
GEN1_SYNC_STATUSWaiting for operator sequence
GEN1_LOAD_SHARE_STATUSNot active
GEN1_BREAKER_STATUS_ECSOpen feedback
GEN1_ALARM_WORD_10000 0000 0000 0000
GEN1_SHUTDOWN_WORD_10000 0000 0000 0000

GEN-2 Controller Screen Placeholder

Same ECS-200 layout as GEN-1, using GEN2 tag prefixes, GEN-2 breaker status, and the second SEL-700G relay context.

GEN2_KW0kW
GEN2_FREQ_HZ60.00Hz
GEN2_ENGINE_RPM0rpm
GEN2_BATTERY_VDC24.7VDC
GEN2_COMMON_ALARMClearstatus
GEN2_AVAILABLEReadyvirtual tag

GEN-2 Links To Add

ECS-200 ReadsElectrical, engine, alarms, starts, hours
SEL-700G RelayGenerator protection, sync check, trip targets
Hardwired I/OStart, stop, lockout, available, running
RTAC VirtualsReady, blocked reason, sync status, comms fail
Cover

Clickable One-Line

The first HMI screen is a simplified station map with links into breaker relays, feeder relays, transformers, and generator controllers.

Controls

View First, Command Later

Use these screens for status, alarms, and diagnostics first. Any command buttons should be added later with permissions, confirmation, and hardwired checks.

Next

Point Map Tie-In

When final register and relay maps are complete, each block can bind to RTAC tag names, addresses, scaling, quality, and timestamps.

Project Tracking Checklist

Checklist imported from the end-of-October Goldrush workbook. Use the checkbox on each row as work is completed; completion state is shared through the project API.

0Total Tasks
0Complete
0Open
0%Completion
DoneWhenCategoryTaskAI

Completion checkboxes save to the shared project tracker.

RTAC Loop Philosophy

Guidance from the checklist workbook for what belongs in RTAC supervisory logic versus generator/controller real-time control.

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