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Installation Guide
LEBE5294-09
Contents
SECTION CONTENTS
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Application and Installation Guide EP Applications, Engine & Generator Sizing
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Temperature rise is the increase For standby power, the F class has
in winding temperature above the a 130°C temperature rise limit or
ambient temperature. Ambient 180°C total temperature:
temperature is the temperature of 40°C + 10°C + 130°C
the cooling air as it enters the
ventilating openings of the The H class has a 150°C
machine. temperature rise or 200°C total
This temperature rise occurs temperature limit:
because of the flow of current in 40°C + 10°C + 150°C
the windings and internal losses
that occur in the machine during
operation. Voltage plays a key role in
generator rating and must be
The most common classes of considered. In some cases,
generators are the “F” and “H” generator voltage will not match
class. For all classes, NEMA the preferred operating voltage.
assumes operation at 40°C ambient A voltage regulator can provide
or lower. The temperature rise voltage adjustment capability,
limits also allow for a 10°C margin however, when “dialing down”
for hot-spots. A hot-spot is the spot generator voltage, the current will
in stator windings with the highest increase for a given rating. This will
temperature. increase generator heat and may
Table 2 shows temperature rise require generator derating. An
for F and H class generators at alternative to generator derating is
various ratings. to use a larger generator to
Genset maintain the standard rating.
Generator Temperature Package
Class Rise °C The standard set by NEMA
Rating
F 80 Continuous
allows a generator to be adjusted
H —
up or down by five percent (± 5%)
F 105 Prime as installed. Cat generators typically
H 125 Prime have a minimum 10% dial down
F 130 Standby capability; in some cases this may
H 150 Standby result in a derate. Some generators
are specifically designed as broad-
Table 2 range and may not require derating.
A check of the manufacturer’s data
For prime power, the F class has is recommended when using
a 105°C rise or total temperature generators at “off-design” voltage.
limit of 155°C (40°C ambient
temperature + 10°C hot-spot margin Generator Mapping Limits
+ 105°C temperature rise) or less. Figure 1 is a reactive capability
chart for a salient-pole generator.
The H class allows for a 125°C rise A load point within this area
or total temperature limit of 175°C defines the:
or less:
40°C + 10°C + 125°C • Active Power
• Reactive Power
• Apparent Power
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EP Applications, Engine & Generator Sizing Application and Installation Guide
such as generator winding protection Color chart guide for selecting the
on main stator windings, space heaters, generator winding type:
and over-sizing to satisfy application The winding description in each of the nine
requirements. boxes is the winding type Caterpillar
recommends. However, it is not practical to
Installation environment. place any actual values on the axis, it is
Generator sets installed in a harsh required the users make individual
environment, subject to abrasive decisions, and consider all other factors
when making a selection. Therefore the
(sand, salt, or dust) or corrosive color-coding is to guide the thought and
(salt or chemicals) air-borne deliberation process when making the
materials, as a priority, should be selection:
form wound construction. It is noted Green Winding is applicable and
that lower power generators are recommended in majority of cases.
Yellow Use extra caution when selecting
typically not available with form the winding type for this environment. The
wound construction. In cases where user must understand and research all
random wound construction is factors of the application, including factors
utilized in harsh environments, the not listed in the table 3 (including customer
optional space heaters and specifications/requirements), if applying a
random wound generator into these
generator winding protection on applications to avoid premature winding
main stator windings should be failures.
selected and applied.
Type of load. High harmonic Environmental Conditions
inducing and non-linear loads Various environment or site
adversely affect generator windings; conditions that impact an engine or
they may cause the winding’s end generator selection include altitude,
turns to destructively vibrate, temperature, physical harsh
leading to insulation cracking, and environments (defined as any or all
making the generators more of the following conditions:
susceptive to moisture failures. condensing humidity, salt, dust, and
sand), and electrical harsh
The form wound generators are environments (include for example
inherently more robust and suitable non-linear loads, high inrush
for these applications. Oversizing loading, and repetitive cycling of
generators is also a consideration loads).
and advised for random wound
generators exposed to this type of An engine rating is primarily
loading. limited by structural and thermal
limits. These limits include
maximum cylinder pressure during
combustion, turbocharger speed,
exhaust gas temperature and in
natural gas engines, fuel type.
Where an engine operates relative
to these limits will determine the
maximum altitude and ambient
temperature for a given rating.
When an engine exceeds the
maximum altitude or ambient
temperature, the engine must be
derated.
Altitude and temperature most
heavily influence engine ratings.
Table 3 The higher the altitude, the lower
the air density. Clean dense air is
needed for efficient combustion.
Likewise, an increase in
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Application and Installation Guide EP Applications, Engine & Generator Sizing
Transient Response
Whenever a load is applied to or (kVAR) changes based upon the
removed from a generator set, the voltage regulator settings, the total
engine speed rpm, voltage and capacity and dynamic characteristics
frequency are temporarily changed of the generator set and the electrical
from its steady-state condition. This inertia of the other loads in the
temporary change is called transient system. On removal of load, the
response. When a significant load is engine speed increases momentarily
applied, the engine speed (generally referred to as overshoot),
temporarily reduces (generally then returns to its steady-state
referred to as frequency or voltage condition. The time required for the
dip) and then returns to its steady- generator set to return to its normal
state condition. The degree of this dip steady-state speed is called recovery
depends on the amount of active time. This is illustrated in Figure 2.
power (kW) and reactive power
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Figure 3
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Figure 4
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Figure 5
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power can be determined. First, find the air entering the cylinders. A
the BMEP of the engine at rated turbocharger can increase pressure
speed; BMEP levels are shown for which will increase density. Density
each rating in the performance data of the air can also be increased by
of the TMI. cooling the hot, compressed air
If the percentage of block load is with a heat exchanger called an
under the first load step curve, the aftercooler. A separate water
block load can be accomplished in supply, jacket water, or radiator
one step. airflow can be used for this cooling.
If the percentage of the block load The configuration of the air
is greater than the first load step systems can also have an effect
curve but smaller than the second on the transient response. A
load step curve, it will take two load turbocharger equipped with a
steps to reach desired power. wastegate allows a larger
turbocharger to be used but limits
If the percentage of block load is the turbo boost pressure under
greater than the first two load step normal operating conditions. The
curves but less than the third load engine runs faster and therefore
step curve, it will take three load increases airflow without
steps to reach desired power. overspeeding. Another example is
Load blocks and response to the ability to decrease the transient
block loading is one of many response by increasing the number
considerations when sizing a of turbochargers. This would allow
generator set. Many turbocharged the engine to run at the same BMEP
and aftercooled four-stroke diesel but have a different transient
engines will not accept 100% block response. Inlet air pressure in a
load in one step. Always investigate turbocharger affects the air density
to ensure the selected generator set as well. A smaller nozzle in the
will meet application requirements. turbine housing of a turbocharger
increases air velocity which causes
Engine Configuration the turbocharger to operate at a
The way an engine is configured higher speed, thus, increasing boost
can affect the size of genset needed. and airflow. An engine equipped
Air System with water-cooled exhaust
The load acceptance behavior of manifolds will transfer less heat to
an engine also depends on the type the turbo-charger, making it less
of air supply to the combustion efficient during short periods of
system. Maximum engine power acceleration.
may be airflow restricted. Power
can only be increased if airflow and Gas Engines
fuel rate are increased. Engine Cat gas engines are naturally
airflow is determined by aspirated (NA) or turbocharged-
aftercooled (TA). Atmospheric
displacement of the engine, engine conditions affect the way an NA
speed, and engine inlet air density. engine can draw air into its system.
More dense air allows the generator An NA engine’s load capability is
set to perform more efficiently; thus directly affected by altitude and
a quicker response to varying loads. ambient temperature. TA engines
For a given displacement, or given have a turbocharger which
size of engine, more speed compresses air which increases its
produces more airflow. The best temperature. A separate aftercooler
way to increase airflow at speeds is used so that air density and
which are compatible with 60 Hz or detonation margin is increased.
50 Hz is to increase the density of TA engines can be derated so that
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Customer Requirements
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Figure 9
Figure 10
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Figure 13
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Concept is feasible only where customer Concept is viable even for customers with
experiences severe demand “spikes” and relatively flat load profiles
high demand charges
Customer decides when to run generators Utility dictates operation when utility
cannot meet all of its customers’ demands
If generators are installed for the sole purpose of taking advantage of peak-shaving
incentives, the customer gains the additional benefit of acquiring backup protection
against utility outages
Figure 14
Peak Sharing
In a typical peak sharing
arrangement, the customer installs
and operates generators of specified
capacity when directed to do so by
the utility company. Under many
peak sharing contracts, utilities
compensate the customer for each
time they operate their onsite
generators. The differences between
peak shaving and peak sharing are
outlined in Figure 14.
Co-generation
Co-generation is the term used to
describe the load management Figure 15
system that produces electricity for
lighting and equipment operations As shown in Figure 15, loads are
while at the same time it utilizes the arranged into descending order of
waste heat produced in the exhaust magnitude based on the percentage
for heating, cooling, or generation of of the total load. Generator sets
process steam. Co-generation plants powering the base load operate for
can operate independently of the the duration of a 24-hour period.
utility or in parallel so the cogenerator Generator sets powering the
can purchase from or sell power to intermediate load are activated for a
the utility. limited period when the load
Load Duration Curves increases to a specified level.
Load duration curves can also
represent loads.
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Table 8
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Figure 17
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EP Applications, Engine & Generator Sizing Application and Installation Guide
you must always assume that total In summary, all loads need to be
time-current characteristics of all analyzed so that the correct size
motors and other loads starting at generator can be matched to the
the same time will not exceed the load. When sizing a generator for an
short-term generator set rating. application, the steady state load
Figure 18 illustrates how demand and maximum transient load need
and diversity factors are used in to be considered.
generator set sizing. Frequency Dips
Frequency dips are related to the
size of load being connected. Twenty
to 25% maximum frequency dip is
the standard limit. A frequency dip
above 35% may cause the engine
difficulty in recovering. Frequency
dips are normally more tightly
controlled than voltage dips
because they are typically
connected to more sensitive
electrical equipment.
Block Load & Standards
The NFPA (National Fire
Protection Association) standard
110 requires that a generator set
Figure 18 must be capable of picking up a
100% block load. It does not specify
frequency and volt deviations.
In Figure 18, connected loads of ISO 8528 (2005) also has transient
300 kVA, 100 kVA and 500 kVA are response standards that are
shown. After calculating demand discussed in the Engine Ratings
factors for each of the same loads, section of this guide. The
the corresponding demand loads performance class relevant for the
are 240, 100 and 350, respectively. application must be followed to be
When combined, the total demand within the standard and achieve
load on the system is 690 kVA. maximum performance.
When the diversity factor is 1.0, the
total 690 kVA is divided by 1.0 to get Starting Requirements
690 kVA. To meet this load, a The time it takes to initiate a
generator set rated at a standard genset startup and when it is ready
size of 750 kVA is needed. to accept load is defined as its
However, a different diversity starting requirement. Starting
factor on the same system will require-ments will vary depending
change the total kVA needed. If the on the application. A typical starting
diversity factor is 1.4, for example, requirement is 10 to 30 seconds.
690 kVA divided by 1.4 equals Load Acceptance
492 kVA. Hence, a generator set Load Acceptance is the point at
rated at 500 kVA would satisfy the which breaker closure is initiated.
load.
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Correction Factors
Emission levels are affected by the
Diesel Natural Gas
engine rating, speed, turbocharger, Emission
timing, fuel and ambient conditions. g/bhp-h Catalytic Low
NA TA T Converter Emission
Higher ambient temperature and Nitrogen Oxide
12.0 15.0 19.0 1.2 2.0
higher altitudes increase nitrogen (NOx)
dioxide and particulate emissions. Carbon
Monoxide 3.5 2.0 1.5 1.0 1.7
When engines are tested in the lab, (CO)
they are tested to specific standards Hydrocarbons 0.4 1.5 1.5 0.5 0.35
(NMHC)
outlined in ISO 8178-1 in regards to
temperature, barometric pressure Table 11
and fuel density. The nominal level
of emissions data is derived under Note: Depending on configuration
these conditions. The specific and rating, many engines emit
conditions can be accessed through considerably less emissions.
TMI. Specific emission data is available
from the specific product TMI.
Nominal vs. Not to Exceed
Engine emissions information is Heat Balance
typically published in one of two Before a cooling system is
formats. The first is nominal, which designed, the designer must
is what emissions levels would be understand how much heat is being
expected from a nominal engine; rejected through each of the cooling
while the second level is not to circuits. The following guide will
exceed, which is the maximum help interpret and apply the heat
emissions output expected for an rejection data.
engine. It is important to Heat balance is a term used to
understand these levels when describe the following:
comparing competitive information
and when providing information to The heat input into the engine
engineering consultants and end equals the sum of the heat and work
users. outputs.
“Not to Exceed” data includes a An example of this relationship is
“Tolerance Factor” to account for shown in the following equation:
paralleling and instrumentation and Work Output
facility variations. If the “Not to
Exceed” value is exceeded during + Total Exhaust
field measurements, it is likely that Heat
the test equipment is at fault or + Radiation
that the engine has a problem. + Jacket Water
Cat engines, at rated speed, will + Oil Cooler
not exceed the values specified in + Aftercooler
Table 11.
= Total Heat
Input
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Figure 20
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Over
C 2.00 1.90
1.40
Not Not
D 2.75 specified specified
Table 13
120(f) 120(60)
Synchronous = 1200
= # =
Speed 6 rpm
Figure 23 Poles
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Table 16
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Figure 29
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Figure 32
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60 Hz - 230
50 Hz - 380
Volts Locked
Horsepower Rotor Design Horsepower Volts Locked Design
Letters Rotor Current, Letters
Current,
Amperes* Amperes **
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Figure 34
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Advantages Disadvantages
Autotransformer
1. Provides highest torque per amp of line current. 1. In lower hp ratings, it is most expensive
2. Taps on autotransformer permit adjustment of design
starting voltage.
3. Closed transition starting.
4. While starting, motor current is greater than line
current.
5. Low power factor.
Resistor
1. Least expensive reduced voltage starter. 1. Requires special motor design for
2. Closed transition starting. voltages higher than 230 v.
3. Most dual voltage motors can be started part
winding on lower of two voltages.
4. Small size.
Start Delta
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Autotransformer – Closed
Figure 38
Autotransformer — Closed
Transition
An alternative to open transition
switching, is closed transition.
This technique minimizes shock
by providing continuous flow of
current while switching from auto-
transformer tap to full voltage.
Closed transition switching, though
involving slightly more complex
switching, is preferred for
autotransformer starting. Auto-
transformer starters are
magnetically controlled. Three taps
on the transformer secondary are Figure 39
set for 50%, 65%, and 80% of full
line voltage. These three contactors,
a timer, and a transformer make up
the starting device. This starter is
very smooth in acceleration
and allowance starting time is 30
seconds. It is the most expensive of
all starters.
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Figure 41
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Solid State
Figure 43
Solid-State Starter
Solid-state starters offer many
options in achieving desired starting
characteristics. Solid-state starters
adjust torque, acceleration ramp
time and current limit to cause a
motor start which has a controlled
acceleration. Solid-state starters
offer smooth, step-less motor
starting by varying the conduction
angle of SCR’s. The conduction Figure 44
angle varies from 20 to 100% which
in turn controls the motor voltage The user adjusts the control to
from 40 to 80%. They have the deliver the best starting
advantage of operating without characteristic for the application.
mechanical parts and large Variations of current and voltage
electrical switching contacts. This limit are sometimes used to achieve
provides a very smooth application linear speed ramp, however the
of power. operating principle of the controlled
The solid-state starter is not to be parameter is always based on
confused with the solid-state voltage control.
adjustable speed drive. With a solid- Voltage Ramp
state starter, circuits are typically Voltage/time ramp increases
only active during starting and voltage until full voltage is applied
therefore do not require additional to the motor terminals. Constant
generator capability to kVA is maintained, and sudden
accommodate voltage distortion torque changes are eliminated, as
due to the SCR’s. If the solid-state
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Voltage Ramp
Figure 46
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When planning systems with SCR Static systems isolate critical load
devices, the control manufacturer through solid-state devices which
must be informed that a limited use batteries to bridge power
power source (generator set) will be interruptions until a genset is
used. The system can then be available to power the system.
designed to minimize distortion UPS’s can also be used to perform
problems. Limiting SCR loads to an orderly engine shutdown to
66% of a Cat generator’s prime minimize restart damage.
power rating ensures regulator
control and avoids generator Static UPS systems use static
overheating caused by harmonics. components to provide quality
Applications requiring high load power to critical equipment,
factors must be analyzed on an independent of the quality or
individual basis. availability of the normal power
source. The simplest systems
Welding Loads consist of a rectifier (converter), a
Welders draw erratic fluctuating DC storage battery bank, and an
current. These current fluctuations inverter.
produce voltage waveform The rectifier, sometimes called
distortion due to relatively high-load converter, is a device that converts
source impedance. Generator sets AC current to DC current.
may require significant derating
with welder loads. The inverter uses Solid State
technology to convert DC to a
Uninterruptible Power Supply (UPS) waveform that is then filtered so it
A UPS system is an assembly of is suitable for powering the critical
equipment used with electrical load.
loads sensitive to power source
disturbances or that require A bank of storage batteries
absolute continuity of power. The “floats” on-line to provide seamless
UPS can store energy for a period DC power to the inverter in the
during power outages. The UPS event of power source loss to the
continually conditions power and if rectifier. The batteries get their
the normal power source is not restoring charge and standby float
available, the UPS provides power charge from the rectifier’s DC
to the critical load until the standby output.
power generation can come on-line. The DC output of the rectifier
The generator set should be sized to provides for two functions during
the UPS rating, not the load. the time when an AC power source
Continuity and isolation from is available at its terminals.
power source disturbances can be 1. It provides regulated DC to the
assured by using either a rotary or a inverter for powering the
static UPS system. critical load.
Rotary systems use a motor- 2. It maintains the “state of charge”
generator set to isolate the critical on the bank of DC batteries;
load combined with kinetic inertia
storage technique or batteries to including recharging
carry the critical load while cranking if the state of charge has been
a diesel engine. depleted by a recent normal
power outage.
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Figure 49
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Figure 50
Static UPS System
Figure 51
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Figure 53
Figure 54
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Figure 55
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Where: Where:
P = Power Loss in Watts P = Power Loss in Watts
L= One-way Length of a Circuit L= One-way Length of a Circuit
in feet in feet
CM = The Cross Section of a CM = The Cross Section of a
Conductor in Circular Mils Conductor in Circular Mils
I = Represents Current I = Represents Current
Example Example
Assume a single-phase motor Assume a three-phase motor
rated to deliver 7.5 hp at 115 V is rated to deliver 100 hp at 230 V
connected to a power source via a connected to the power source via a
200 foot, No. 1 AWG copper wire 400 foot cable sized at 250 MCM.
sized at 83,690 CM. Also, assume Also, assume the motor draws 248
the motor draws 80 amperes at full amperes at full load. What is the
load. What is the power loss? power loss?
Solution Solution
Use the formula for a single-phase Use the formula for a single-phase
motor: motor:
24 x 200 x 36 x 400 x
802 =P 2482 =P
83,690 250,000
The result is a 367 watt power The result is a 3,543 watt power
loss. loss.
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50 x 1000 = 173.5
1.732 x 208 x 0.8 Amperes Figure 58
2. Find the coil current capacity
remaining for the single-phase
load:
334 – 173.5 = 161 amperes
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Figure 59
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hp kW Full-Load Efficiency
5 to 7.5 4-6 0.83
10 7.5 0.85
15 11 0.86
20 to 25 15 to 19 0.89
30 to 50 22 to 37 0.90
60 to 75 45 to 56 0.91
100 to 300 74.6 to 224 0.92
350 to 600 261 to 448 0.93
* Efficiencies are significantly influenced by the motor class.
Table 22
Figure 60
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Figure 61
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Table 23
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kVA of AC Circuits
Table 24
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Voltage and
Current Drawn Current Examples
Waveforms
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Figure 63
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Figure 64
Figure 65
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Generator Heating
Generator Considerations Generators are designed to
Generator System Protection provide a given output at rated
The application of synchronous fundamental frequencies of 50 or
generators into any installation 60 Hz. Design considerations
requires at least a minimum amount include making the most effective
of protection to protect the use of active material to meet
generator and prime mover against acceptable limitations of
faults and abnormal operating temperature rise. (More on this
conditions. The customer needs to topic is found in Engine Ratings
balance the expense of applying a section.)
particular protective device (relay, Generator Reactance Impact
surge arrestor, etc.) against the Subtransient reactance (X”d) is a
consequences of losing a generator primary indicator of the amount of
or prime mover. When considering harmonic distortion to be created
what protective devices to use, the by a non-linear load. Current reacts
potential loss of a generator or with impedance to cause voltage
prime as well as the impact of loss drop. The internal reactance of a
of service needs to be considered. generator to instantaneous current
The extent of the protection system change is the direct axis sub-
design will depend on the size and transient reactance (X”d). A
relative value of the generating unit. generator with the lowest per unit
There is no standard solution based value of X”d at a given load will
on the generator set power rating, typically have the lowest value of
however large critical units tend to total harmonic distortion under non-
have extensive protection systems linear load conditions.
with redundancy while smaller less The internal reactance of a
critical units may have a subset of generator due to line-to-neutral or
the primary protection provided for unbalanced loading is the zero
the larger unit with little if any sequence reactance (Xo). Any 3rd
backup protection. It is the harmonic currents, also known as
responsibility of the customer to triplen harmonics, produced by the
understand the site and application load will not cancel in the neutral
and to provide the appropriate and the result is neutral current
amount of protection. This will flow, even with balanced loads. The
require an evaluation of the triplen harmonic circuit is the same
potential risks, and a commercial as three single-phase circuits with
evaluation of the cost for protection three parallel line-to-neutral
devices versus the cost of failed branches sharing common neutral.
equipment.
Phase conductor heating from the
For additional information 100% rated neutral 3rd harmonic
regarding protective devices, current and other effects will add
including applications that are not approximately 6 to 7% of additional
using paralleling switchgear heat. This relatively high 3rd
reference Generator Paralleling harmonic would only require 6 to
Switchgear A&I Guide (LEBW7543). 7% derating of the generator. It can
create distortion of the generator
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Figure 67
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Figure 71
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Figure 72
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• Regulator Design: Automatic
or analog voltage regulation
(AVR) of dissimilar design
may be used when paralleling
generators. When constant
voltage regulators are
paralleled with volts-per-Hertz
types, imbalance during
transient load changes can be
anticipated.
Figure 73 As load is suddenly applied,
constant voltage units attempt to
Usually, identical generator sets supply the total requirement. As the
operate in parallel without constant voltage generator drops
problems. When paralleling unlike frequency, the volts-per-Hertz unit
units, however, the following effects begins to share load. The temporary
must be considered. load imbalance passes, and kW load
is shared between generators.
• Engine Configuration:
Response to load changes Once two or more generators are
will be affected by engine paralleled, it is as though they are
size, turbocharger, governor mechanically coupled together.
type, and adjustment. They will operate at the same speed
Temporary unbalance of kW but not necessarily have the same
loads during load change is power output. Each engine’s power
likely, but can quickly contribution is controlled by the
stabilize. relative fuel system output.
• Generator Design: Circulating Droop and Governors
currents and harmonic Droop is when the governor
currents add to basic load reduces speed with an increasing
current, increasing coil load. Speed is lowest at full load
temperatures, and causing and highest at no load. Droop is
circuit breaker tripping. expressed as a percentage of rated
Circulating current is speed. A 2 to 3% droop is typical.
minimized by correct Two isochronous units, operating
regulator adjustment. in parallel, will operate at constant
Harmonic interaction speed (no droop) and be stable at
between generators must be either no load or maximum load.
calculated to determine Loads in between will shift
compatibility. randomly between the two
generators. Electronic governors
can be installed to limit this
instability by causing load to be
shared more evenly. This strategy is
especially effective in allowing
many units of unequal size to share
load in proportion to their size.
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