Case Study: Mudra Building Materials Self-Use Power Generation Project, Nigeria

Project Overview

This is the Mudra Building Materials Self-Use Power Generation Project located in Nigeria. A 3000 kW captive generator set is adopted for the project. We supplied a complete set of generator protection panel and synchronizing panel featuring multi-dimensional generator fault protection and safe grid paralleling capability.functions.

Item	Details
Project Name	Mudra Building Materials Self-Use Captive Power Generation Project
Location	Nigeria
Secondary Equipment EPC Contractor	Shandong Jun Industrial Co., Ltd. (China)
Generator Capacity	3000 kW captive generator set
Supplied Equipment	Generator Protection Panel; Generator Synchronizing Panel

Equipment Functional Scope

Generator Protection Panel

Covers complete generator protection functions:

• Generator differential protection (87G)
• Differential instantaneous overcurrent protection
• Negative sequence overcurrent protection
• Overvoltage protection
• Thermal protection
• Excitation inter-tripping logic
• Generator rotor earth fault protection (64R)

Generator Synchronizing Panel

Realizes automatic/manual synchronisation for safe generator paralleling and grid connection.

The cement & building material factory relies on this genset to stabilise power supply against unstable local utility grid in Nigeria. Reliable generator protection and controlled synchronisation are critical to avoid unplanned production shutdowns.

Client Communication & Commercial Process

The project client is a Chinese contractor operating overseas, enabling smooth and efficient technical communication.

1. We first provided complete datasheets and product manuals for the generator protection panel and synchronising panel.
2. Client reviewed all technical specifications and confirmed function compliance.
3. Commercial negotiation and pricing discussion followed technical confirmation.
4. Formal sales contract signed; mass production commenced after deposit receipt.

Bill of Materials

No.	Description	Specification & Model	Unit	Qty
I	Generator Protection & Control Cabinet	VIP-9000FDJP	Set	1
1	Main Generator Protection & Control Device	VIP-96S98	Unit	2
2	Generator Backup Protection & Control Device	VIP-96S88, with 4~20mA analog output	Unit	2
3	Rotor Earth Fault Protection & Control Device	VIP-96S89, with 4~20mA analog output	Unit	2
4	Line Protection & Control Device	VIP-96S71	Unit	1
5	Changeover Switch	LW12-16/5858.3	Pc.	3
6	Power Surge Protector	KDM/MD220-20	Unit	1
7	MCB	HG45Z-63 2P C3	Pc.	6
8	MCB	HG45-63 3P C1	Pc.	2
9	Power Socket	AC30-10530, 10A/250V, 5-hole	Pc.	1
10	Cabinet Internal Lighting	AC220V	Set	1
11	Control Cabinet & Accessories	2260800600mm	Set	1
II	Synchronizing Panel	VIP-9000TQP	Set	1
1	CPU Module	6ES7 288-1ST40-0AA1	Piece	1
2	Frequency Meter	VIP-926-F/C900DL, AC0-100V, with RS485 communication, Power supply DC220V	Pc.	2
3	Voltmeter	VIP-926-V/C900DL, AC0-100V, with RS485 communication, Power supply DC220V	Pc.	2
4	Multi-function Digital Meter	VIP-926-E24/C900DL, AC100V 5A, with RS485 communication	Pc.	2
5	DC Voltmeter	VIP-926-V/C900DL, DC0-200V, with RS485 communication, Power supply DC220V	Pc.	2
6	DC Ammeter	VIP-926-I/C900DL, DC0-75mV, with RS485 communication, Power supply DC220V	Pc.	2
7	Rotor Ammeter	VIP-926-I3/C900DL, 5A, with RS485 communication, Power supply DC220V	Pc.	2
8	Synchroscope	MZ10, 100V	Pc.	1
9	Synchronism Check Relay	DT-1/200, 100V, Front-mounted wiring	Pc.	1
10	Automatic Precise Synchronization Unit	PTQ2000A1, 100V	Pc.	1
11	Switching Power Supply	MDR-100-24	Pc.	2
12	Auxiliary Relay with Socket	MY4N-GS DC 24V	Set	16
13	Manual/Auto Changeover Switch	LAY50-22D-22X/K	Pc.	1
14	Active & Reactive Power Adjustment Switch	LAY50-22D-20CXS/FFU	Pc.	2
15	Synchronizing Switch	LW12-16/4.1366.4	Pc.	1
16	Changeover Switch	LW12-16/5858.3	Pc.	1
17	Push Button	LAY50-22D-20T/G	Pc.	5
18	Bicolor Indicator Lamp (Green / Red)	AD56-22DSS/RG23	Pc.	4
19	Changeover Switch	LW12-16 Y/.6	Pc.	4
20	AC MCB	HG45-63 2P C3	Pc.	2
21	DC MCB	HG45Z-63 2P C3	Pc.	6
22	Isolation Transformer	BK100VA, 100V/100V	Pc.	2
23	Power Socket	AC30-10530, 10A/250V, 5-hole	Pc.	1
24	Cabinet Internal Lighting	—	Set	1
25	Control Panel & Accessories	2260*800*600mm	Set	1

Production & Delivery

All panels underwent in-house wiring inspection, functional simulation testing before shipment.

Goods were packed according to overseas export standards and delivered to designated receiving address in Linyi City, China, as required by the EPC contractor for consolidated container loading towards Nigeria.

Site Commissioning & Technical Support

To facilitate smooth field commissioning in Nigeria, we compiled a dedicated commissioning manual containing wiring check procedures, protection setting guidance, synchronisation operation steps and typical fault troubleshooting.

During on-site testing, one critical issue occurred:

Fault Description: The generator differential protection triggered unintended nuisance tripping under normal operating conditions.

Root cause: Improper differential protection setting values mismatched actual generator operating parameters.

Our technical team carried out real-time remote technical guidance:

• Analysed fault recording data uploaded from site
• Recalculated differential pickup thresholds and bias characteristics
• Guided site engineers to update relay settings step by step
• Performed repeated on-load verification after parameter adjustment

Final Acceptance

After optimising protection settings and completing full sequence commissioning tests, all protection functions and synchronisation logic operated stably without abnormal tripping. The system passed final site acceptance and has been running continuously for the building material plant’s production load.

Key Project Takeaways for EPC & Plant Engineers

1. Factory default relay settings cannot fully adapt to every on-site generator; differential protection parameters require project-specific calculation. Improper settings are a common cause of nuisance tripping.
2. Comprehensive pre-shipping documentation (commissioning manual, wiring drawings, setting template) reduces on-site trial-and-error time for overseas projects.
3. Timely remote engineering support effectively resolves commissioning obstacles when local professional resources are limited in African sites.
4. Separately configured generator protection panel + synchronising panel delivers clearer functional partitioning and easier maintenance compared with integrated single-panel solutions for 3 MW captive generators.

Why Work With Us for Generator Secondary Control Equipment

• Standardised generator protection panels covering ANSI standard protection elements for medium/large captive gensets
• Independent synchronising panels supporting manual & automatic paralleling
• Complete pre-delivery testing, export-standard packaging
• Continuous remote commissioning support and relay setting consultation for global sites
• Customisable logic modification according to EPC project requirements

If you have ongoing captive power, industrial self-generation or generator paralleling projects in Africa and need generator protection & synchronisation solutions, contact our engineering team for technical proposal and quotation.