GEN MASTER For DG set/Utility application with dual control

Use of datar Gen Master with DG Set and Utility Power

It is the load which lowers the power factor of the power delivering system. When power is drawn from utility, it
is desirable to improve the power factor to unity. But when the power drawn from the DG Set, the power factor
is not allowed to be improved beyond 0.95 as recommended by the DG set manufacturer. Also after the DG
set is started, the load is increased on it gradually. While the load is less and if a fast switching APFC system is
connected to it for PF correction, due to capacitor connection the DG set runs overexcited and starts hunting.
These specific requirements does not allow the customer to use the same APFC system with DG set that is in
use while power is drawn from utility. The customer needs to have two different APFC systems i.e. one for
using on utility and other one for DG set, calling for additional investment.
datar Gen Master comes with the APFC relay with duel setting. The customer can preset the target power
factor that is to be achieved while using DG set or utility power. Customer need to preset it only once and leave
it to the controller to achieve the target PF. The controller target power factor setting automatically changes
over to another setting whenever power fails and load is transferred from utility to DG Set. The APFC relay that
comes with Gen Master has the program not allowing to switch on the capacitor banks until the load on DG set
loaded upto 15-20%.

Load Current Sensing
The Load CTs are placed at the common point of supply, going to the load. If this is not possible then two sets
of CTs are required, one to be placed at utility side incomer and another set at DG set side incomer. When
utility power fails, the contactor will automatically change over to DG set side CTs. The signal is taken from DG
AMF panel and will have interlocking with APFC system.

Benefits
These particular features incorporated in the datar Gen Master, enables the customer to derive following
benefits.
To increase the load on DG set further as required.
Saving in fuel cost required for generation of electricity.
Use same APFC system for both DG set and utility power.

Compatibility of datar Gen Master with DG Set
datar Gen Master is the only APFC System, which can be put into the electrical network while power is being
fed from the DG Set. This has been achieved through constant and persistent efforts of our R & D to develop a
system having following features
In conventional Automatic Power Factor Correction System when capacitor is switched ON with the help of
contactor, surge of inrush current drawn from the generator is as high as 200 times the rated current. This
result in voltage dip and increases the excitation to stabilize the level of voltage generated. This in turn causes
over-voltage in the network and the generator works in unstable mode, which further causes hunting. datar
has developed RTPFC System which switches ON the capacitor on zero point on AC waveform so that the
inrush current is totally eliminated and above phenomenon does not occur.
In the conventional Automatic Power Factor Correction System usually power factor of only one phase is
sensed and the decision of capacitor insertion/ withdrawal is based on this measurement which may cause
over compensation or under compensation of the network. Over compensation is not desirable as exciter
circuit faces problem due to over compensation. In case of under compensation the generator capacity is not
utilized fully. In conventional system there is an intentional unavoidable delay of two minutes provided between
the sensing and the corresponding correction which may cause under/ over compensation continuously.
datar Gen Master continuously monitors the P.F., Current, kVAr Compensation required for each phase
individually and based on the data collected it corrects the power factor on cycle to cycle basis by switching
ON the maximum capacitor instantaneously by pre-programmed permutations and combinations of the
capacitor banks steps in order to achieve the set target P.F. While doing so it takes utmost care of not to
overshoot P.F. beyond the set value and thus there is no over compensation / under compensation. Due to the
above features of datar Gen Master the DG Set can be additionally loaded and there is no over compensation
or under compensation and there is no chance of over excitation occurring due to introduction of unnecessary
capacitors. However, customer is still in a position to enjoy the benefits of improved P.F., which helps in drastic
load growth and reduction in fuel consumption proportionately.

DG Set Loss Reduction by datar Gen Master
Reducing the current output from alternator without altering the loading conditions can reduce the alternator
losses. Improving the power factor at the output of the alternator can conveniently do this. Hence, improvement
in the power factor in alternator leads to reduction of fuel consumption in DG sets. Conventionally capacitors
are not used along with DG sets, because by using fixed capacitors there is a danger that the PF can become
leading under lightly loaded condition which is highly undesirable in DG set operation. And also when
capacitors are connected to the network, heavy current, as high as 200 times rated current, may be drawn
through the DG set which has got harmonics contents also. This leads to polluting the network and which is
undesirable. Hence only Automatic Power Factor Correction System of datar Gen Master should be used with
DG sets. The target Power Factor can be set to 0.93 to 0.95 for optimum performance.
The following example gives an approximate calculation which shows the impact of power factor improvement
on reduction in alternator losses and accrued savings in Diesel consumption.
Consider a 3 Phase, 415 V, 50Hz, 320 kVA DG set used in an industry for 3000 hours/year with an average
load of approximately 250 kw at 0.86 PF. What is the fuel/cost saving if PF is improved to 0.95? The full load
copper loss of the alternator is 5 kW and average yield of the DG set is Rs. 3 kWh/liter of fuel.

Rated Current of alternator = 320000/ (3 x 415)
= 445. 18 Amp
For 250 kw load current at 0.86 PF = 250000/ (3 x 415 x 0.86)
= 404.42 Amp
Copper loss at this current = (404.42/ 445.18)2 x 5 kW
= 4.1 kW
Reduced Load current at 0.93 PF = 250000/(3 x 415 x 0.95)
= 366.10 Amp
Copper loss at 0.93 PF = (366.10 / 445.18)2 x 5 kW
= 3.38 kW
Reduction in power losses = 4.1 3.38 kW
= 0.72 kW
Energy saved for 3000 hour Operation = 0.72 x 3000 kWh
= 2160 kWh
DG Set Yield = 3 kWh / liter of HSD
Potential savings in HSD fuel = 2160 / 3
= 720 Liters per year
Potential saving in Rs. (@ Rs. 35 / liter) = 25200/- per year



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