Woodward Easygen vs PLC control system

[meehd88]

I am a facility owner currently working on replacing our genset and paralleling switchgear with 6 x 2.5MW CAT 3516c and am being presented with some options on the controls side.

Option 1 - Woodward Easy Gen + SEL 700G for UV/OV protection, sync check
Option 2 - CAT OEM EGP paralleling controls
Option 3 - Russelectric with Allen Bradly PLC + SEL 700G

I am looking for feedback on the options above in terms of reliability and would like to see if there are better options out there today. Main concern is reliability and serviceability. Cost is less of a issue.

 

[TE163]

I can't speak to the other units but I've been very happy with the SEL products.

 

[FreddyNurk]

My personal preference on any of this is go dedicated hardware rather than a PLC. For the examples you've provided this would mean the EasyGen option.
The previous Woodward model was the default standard for quite a few remote power stations I'd been involved in. I've not used them but the EasyGen also comes in a full redundant controller option if required.
SEL makes good equipment too, and has excellent support.

 

[TugboatEng]

The Caterpillar advantage is their local dealer network. Same day service is often available.

The Caterpillar disadvantage is that you may need to take advantage of that service. The OEM packages have to be more inclusive of a broader range of requirements so they tend to be more complicated as a result.

 

[dpc]

If the PLC is to be involved in generator synchronizing, I'd be concerned - they are generally too slow. Woodward + SEL would be my preferred solution.

 

[wcaseyharman]

In 2023 we had a contractor install an Easy Gen and we installed a 700G and a Basler DECS 400 on a 2.5 MW MP45 that powers a microgrid.

We are pretty happy with it.

We have a site with old Caterpillar controls, it seems very confusing to troubleshoot.

Granted, we were heavily involved in the easygen installation so we are much more familiar with it, but it’s worked very well for us.

I will say the easygen custom logic can be quite convoluted and the modbus tag list can be confusing, but it’s a capable box and is pretty flexible.

We have had good luck with PLC based hydrogovernor controls systems, but we’ve never used a PLC based control system for a diesel. The downsides of PLC based systems seem to be they often have limited electric based I/O, so you need voltage, current and power transducers separate from the PLC rack. Synchronizing is typically done by a separate box (now commonly in the relaying or excitation).

Based on what I know, I’d probably go with the Woodward since it’s pretty common and you’ll be able to get support from multiple companies.