synchronization panels

Synchronization panels are mainly designed and used to meet power system requirements. These
panels provide manual as well as automatic synchronizing function for one or more generator
breakers. They are widely used in synchronizing generators and offering multiplexing solutions.
Product Description Synchronizing panels usually consist of:
A Generator Control Unit: This unit automatically matches generator frequency and voltage levels
with that of the bus.
A Syncrocloser Unit: It sends the closing command to the breaker at the exact moment of phase
coincident A Syncrocloser Check Relay: It performs the progressive function of verifying voltage
and phase angle conditions and ensuring that they are within preset limits, before allowing the
breaker to close.
The device is provided with control switches in the front panel. These switches are responsible for
manual raising and lowering of speed and voltage of the generator to match the bus frequency and
voltage before synchronizing. There are volt meters and digital meters in the device that offer
generator and bus measurements.
Synchronizing panel Description
2 DG synchronization panel is required to paralleling of 2 or more DG's it may be as per the load
dependent .one DG will be ON as per the master and other will synch once the Frequency ,voltage
matches with master DG .this is required to share the load.
CRITICAL LOAD
Some Industries have critical process machines which require continuous power supply and any
momentary interrupt can cause substantial production loss. These machines generally run on
Generating set. But when maintenance time of Generator approaches, load has to be cut off from
first generator and transfer to another set to start production immediately, however interruption
while load transferring sometimes not acceptable Synchronization can avoid this momentarily break
in following way, while transferring load to another generator, this generator can be synchronized
with running generator and after synchronization, load can be transferred to second set and first set
can be shut off for maintenance. So your critical load do not have any interruption at all.
VARIATION IN LOAD
Power requirement of industries may vary maximum to minimum in a day. For example if in an
industries load varies from 70kW to 200kW , instead of having single 200kW generator set one can
have two 100kW sets so that during low load single set can be run and as load goes up second DG
can be synchronized. This reduces generator maintenance and prolongs its life. Effectively.
Expansion of Your Plant:
Suppose you have a single Generator of 100kW capacity in your works, capable enough to feed
your entire load. Now you have planning to add new machinery in your industries and that causes
more power requirement, say 200kW. You are left with two option, one is to discard 1MW set and
buy new 200kW set and that you think is expensive, secondly buy another 1MW set and redistribute your load so that each Generating set can feed 1000W power separately which may not be

feasible.
Synchronization of two nos. 100kW Generators can solve the problem. These two 1MW sets can be
synchronized to feed 200kW and act as virtual single 200kW Generators. Any numbers of DG can
be synchronized to meet your increasing load
PROCUREMENT
Sometimes it is difficult to procure single Generators for large capacity due to cost or maintenance
point of view. Instead smaller set synchronized together can be use as alternate.
2X 1250 KVA Auto Synchronizing Panel
FUNCTIONALITY
When mains are healthy, then both the D.G. Sets remain in the standby mode.
When mains fail, Line Voltage Monitor (L.V.M.) senses it. Starting pulses are given to the
Master D.G. Set. (Master D.G.Set is automatically selected by program.)
After satisfactory starting of the D.G.Set 1, voltage is sensed by Generator Voltage Monitor
(G.V.M.). If voltage is healthy, then closing signal is given to D.G.1 breaker and it is closed.
Giving corresponding pulses from the Synchronizing Panel can then automatically start load.
The load is then sensed by KW transducer in the panel & continuously monitored by
Programmable Logic Controller ( P.L.C.)
Engine & Alternator parameters are also continuously monitored by P.L.C. in the Panel. In
case of any fault (e.g. Low Lube Oil Pressure, High Cooling Water Temperature etc.),
breaker is tripped & engine is stopped.
If the load reaches & crosses 80 % of the rated capacity of the D.G. 1, then starting pulses
are given to the second D.G.set from P.L.C.
When D.G.2 starts, then again G.V.M. checks the voltage, and if voltage is healthy, then
breaker 2 is closed.
After closing of the second breaker, Auto load sharing function starts sharing the load
between the two D.G.Sets. The percentage of sharing is directly proportional to their
individual capacities.
Since sharing is proportional to their respective capacities, even D.G.sets of different
capacities can be synchronized successfully.
D.G.sets continue to run in Synchronization until the load is above 80 % of any one D.G.set.
When load comes down below 80 % of any one D.G.set, then the automatic signal is given
to that D.G. & then it starts taking the full load.
After transferring the total load to one D.G. (on which 80 % load is to be connected), the
breaker of the second D.G.is opened. Now one D.G.is taking the load, which is less than 80
% of its rated capacity.
The second D.G. is then stopped after its cooling period.
The programmed is repeated automatically for any variation of the load.
When mains are resumed, then load is transferred to the mains & both the D.G.sets are
stopped after their cooling period.
The percentage setting is programmable which can be set at any value upto say 90 %

 For stable operation even for sudden variations in the load, programmed timers in PLC are
used, which take action only after stabilization of the load.
The total Automatic operation has a manual override. In manual mode, the total operation
can be performed manually.
Auto load shedding facility can be incorporated by suitable programming of PLC. With this
facility, various loads can be brought in or switched off at particular time or for various
intervals.
With the same logic, 3, 4 or 5 sets of equal or different capacities can be Synchronized, with
Auto load sharing facility.
ADVANTAGES OF AUTOSYNCHRONISING & AUTOLOAD SHARING
The total programmed is based on load in KW. Hence the actual sharing, starting, stopping
& transfers are actual load dependent & not on any other unrealistic parameter like voltage,
current. Etc.
Changing of scheme becomes very easy because of changes are made through software only.
There is no changing of wires, adding of components like relays, contactors, which is very
time consuming, cumbersome & requiring additional space.
Along with KW sharing, KVAr sharing & PF sharing is very accurate, because of PLC
programming. There is no possibility of any unequal sharing as regards KW, KVAr & PF.
For any type of load addition or reduction, manual intervention as regards D.G.set operation
is not required. However, in case of emergency manual override is possible.
Special programmers using Real Time Clock (RTC) are possible. With this facility, along
with KW dependent programs; day, date & time dependent programmers are possible.
Because of KW dependent load sharing, optimum utilization of D.G. sets are possible. This
increases D.G. sets efficiency & saves lot of fuel.
D. G.sets are always tried to run with 80 % to 90 % load factor, where we get maximum
efficiency of D.G.sets. This is easily possible with our system.
Because of PLC operation, hardware like relays, contactors, wiring etc is reduced drastically.
This reduces fault points & increases the MTBF of the system.
If any changes are required to be made in future, then there is no need of additional
hardware like relays, contactors etc. There is also no need to make new wiring or changes in
the wiring. All the changes / modifications can be easily made through software only.