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PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
PRODUCT TRAINING
Synchronisation is carried out in order to parallel a Generator onto a live Bus-bar, either in Island mode ( with multiple Generator sets as the only supply), or to the Utility..
Synchronisation can be achieved Manually, Semi-Automatic with Check-sync, or by fully automatic P.L.C systems.
PRODUCT TRAINING
CB1
BUS-BAR
LOAD GEN 2
AVR DROOP CT
MCB
CB2
Consider a simple installation with two Identical Gen-sets, (breakers open circuit). Normally, one (or more), generators will already be connected to the load, and supplying power. (GEN 2 is now closed onto the Bus-bar). It is also normal that the Generator on line (GEN2) will be running at nominal frequency (50 or 60 HZ), while the incoming generator (GEN1), can be running at a higher (NO LOAD), frequency of about 52 or 62 HZ.
PRODUCT TRAINING
CB1
BUS-BAR
LOAD GEN 2
AVR DROOP CT
MCB
CB2 When the relative Engine speeds are different, the Generator waveforms will be rapidly going in and out of phase with each other. To correctly Synchronise A.C. Generators, the frequencies must be ALMOST identical. Frequency (HZ), is the Electrical equivalent of Speed (RPM), which means that the engine SPEEDS must be ALMOST identical. Synchronising equipment is required to monitor the Bus Frequency and the Incoming Generator frequency, to ensure that the Generators are in Synchronism.
PRODUCT TRAINING
EXAMPLE : In this analogy two trucks represent two Generator sets, to be paralleled . If both trucks are travelling at EXACTLY THE SAME SPEED, they will ALWAYS remain the SAME DISTANCE APART, ( IRRESPECTIVE OF SPEED). However, if the REAR truck is A FEW RPM FASTER than the FRONT truck, it will VERY SLOWLY catch up with the truck in front. SYNCHRONISING is exactly the same process, the RATE OF CHANGE in speed must be SLOW ENOUGH to allow the BREAKER to close when the Generators are IN PHASE .
PRODUCT TRAINING
50 HZ
(1500 RPM)
GEN 2
50.1 HZ
(1503 RPM)
Example :- GEN 2 is supplying load and is running at 50HZ (1500 RPM). GEN 1 is INCOMING, and the engine speed has been adjusted down slightly to almost 1500 RPM (for example 50.1 HZ).
As there is a SMALL RELATIVE DIFFERENCE between speeds, the Synchronising equipment should be indicating that the Generators are moving IN and OUT of phase SLOWLY enough to ALLOW TIME to close the breaker.
PRODUCT TRAINING
50 HZ
GEN 2
50.1 HZ
Consider above condition: The Generator is IN PHASE, , but is now about to go OUT OF PHASE. What will happen if the circuit breaker is closed in the final condition above ?
PRODUCT TRAINING
CRASHED
180 INTO PHASE
GEN 2
The Generator waveforms are 180 OUT OF PHASE with each other. As the breaker closes, GEN 1 will instantly try to reverse the rotation of GEN 2. This is IMPOSSIBLE, because of the inertia in the Engine/Generator moving parts. The Generators will be INSTANTLY CRASHED into synchronism. . The transient forces created are both Electrically and Mechanically DESTRUCTIVE Electrical damage can occur to Diodes, Varistors, and Main Stator windings. Mechanical damage may also occur to Couplings, Bearings, and Shaft.
PRODUCT TRAINING
50 HZ
1500 RPM
GEN 2
50.1 HZ
1503 RPM
Example 2 :- GEN 2 is supplying load and is running at 50HZ (1500 RPM). GEN 1 engine speed has been adjusted to almost 1500 RPM (50.1 HZ). The Generator waveforms are SLOWLY moving IN and OUT of phase. The Synchronising equipment indicates that the Generator are IN PHASE. The circuit breaker can be SAFELY closed in the above condition.
PRODUCT TRAINING
OK !
CB1
BUS-BAR
LOAD
GEN 2
AVR DROOP CT
MCB
CB2
When the Synchronising equipment indicates that the incoming Generator (GEN 1) is IN PHASE with the Bus-bar frequency, the circuit breaker can be safely closed.
The INCOMING Generator should ALWAYS be slightly FASTER than the loaded Generator. This ensure that the incoming Generator ALWAYS takes a small proportion of load when the breaker is closed. This will prevent REVERSE POWER protection tripping. The Generators are now IN PARALLEL, the next step is LOAD SHARING.
PRODUCT TRAINING
ACTIVE CURRENT
p.f 1 (kW)
90 90
POWER ( kW )
COS COS
TIME
ACTIVE CURRENT is the USEFUL CURRENT , which is IN PHASE with the Voltage, and provides the POWER, or kWATT component of the load.
INDUCTIVE CURRENT is WASTED or WATTLESS CURRENT, which is LAGGING the Voltage by 90. This is the kVAr component, (POWER FACTOR 0).
The VECTORIAL RESULTANT is the kVA , ( APPARENT POWER). The COSINE of the RESULTANT ANGLE is called the POWER FACTOR ( COS ). CAPACITIVE CURRENT LEADS the Voltage by 90. REACTIVE CURRENT SHARING is controlled by the GENERATORS, (AVR & DROOP).
PRODUCT TRAINING
415V
0% 0.5% 1.0%
409V
0%
50%
PERCENTAGE LOAD
100%
0.5% Voltage Regulation for AVR Types MX321, MA325, MA327 1.0% Voltage Regulation for AVR Types MX341 TO AUTOMATICALLY SHARE REACTIVE LOAD CURRENT, GENERATORS MUST HAVE SIMILAR NO LOAD TO FULL LOAD VOLTAGE CHARACTERISTICS.
PRODUCT TRAINING
415 V
0% 1.0% (SINGLE)
403 V 0% 50%
LOAD AT 0.8 POWER FACTOR
3.0% 100%
At full load 0.8 power factor the voltage DROOP required (single running), is 3%. This is in addition to the normal (natural) voltage regulation of the AVR, and allows the DROOP CIRCUIT to automatically control a % of the voltage. The DROOP SETTING is adjusted on the AVR DROOP CIRCUIT.
A SHORTING SWITCH may be fitted across the DROOP CT for single running.
PRODUCT TRAINING
DROOP
kWATT
403V 400V
CB1 CB1
BUS
EQUIPMENT
GEN 2
403V
AVR 2
0 LOAD LOAD
MCB
403V 406V
CB2 CB2
EXAMPLE: Two similar 400V Generators are required to operate in parallel Generator 2 is incorrectly adjusted to 406V (at no load). GEN 2 is connected to the Bus by closing circuit breaker CB2 GEN 1 is synchronised with GEN 2, and breaker CB1 is closed The resultant Bus-Bar Voltage will be approximately average of the two Generators.
PRODUCT TRAINING
400V
CB1
403 V
403V
GEN 2
AVR
LOAD MCB
406V
CB2 CIRCULATING CURRENT
GEN 1 EXCITATION SYSTEM is trying to PULL the voltage DOWN to 400 V. GEN 2 EXCITATION SYSTEM is trying to PUSH the voltage UP to 406 V. The RESULTANT VOLTAGE will be approximately. AVERAGE of the two Generators This PRESSURE DIFFERENCE (VOLTS), forces CIRCULATING CURRENT into GEN 1. CIRCULATING CURRENT is WATTLESS, (POWER FACTOR 0).
PRODUCT TRAINING
GEN 1
AVR 1
DROOP CT
LAG
CB1
BUS-BAR
403 V
LOAD GEN 2
AVR 2 DROOP CT
PF 11
LEAD LEAD
LAG
HIGH LAGGING CURRENT ( INDUCTIVE, power factor 0 ) is now flowing OUT of GEN 2. HIGH LEADING CURRENT ( CAPACITIVE, power factor 0 ) is now flowing INTO GEN 1. The DROOP CONTROL must REDUCE circulating current to ACCEPTABLE limits. The MAXIMUM acceptable limit for circulating current is normally 8 %.
PRODUCT TRAINING
GEN 1
AVR 1
DROOP CT
LAG
CB1
BUS-BAR
403 V
LOAD
GEN 2
AVR 2
DROOP CT
MCB
CB2 CIRCULATING CURRENT
PF 11
LEAD LEAD
LAG
AVR 2 receives a signal proportional to the circulating current (LAGGING p.f) which DROOPS (DECREASES), the Generator D.C EXCITATION VOLTAGE. AVR 1 receives a signal proportional to the circulating current (LEADING p.f), which INCREASES the Generator D.C EXCITATION VOLTAGE.
PRODUCT TRAINING
GEN 1
VR 1
DROOP CT
LAG
CB1
BUS-BAR
403 V
LOAD LOAD
GEN 2
VR 2
DROOP CT
MCB
CB2
LOAD CURRENT
POWER FACTOR METERS
PF 11 LEAD LEAD
LAG
When the MCB is closed, the DROOP CONTROL must also assist in SHARING the REACTIVE, ( power factor 0 ), component of the LOAD CURRENT.
PRODUCT TRAINING
GEN ENG 1
kWATT METER
AVR 1
DROOP CT BUS-BAR
MCB
ACTIVE CURRENT or kW
kW
LEAD
kWATT METER
ACTIVE CURRENT (power factor 1) is the kWATT component of the load, and is CONTROLLED and SHARED by the PRIME MOVERS (ENGINES).
The PRIME MOVERS (ENGINES), must have similar NO LOAD to FULL LOAD GOVERNOR CHARACTERISTICS, in order to share the ACTIVE CURRENT, (PF1).
PRODUCT TRAINING
HORSE POWER is the mechanical equivalent of kWATTS, (ELECTRICAL POWER). kWATTS = CURRENT X VOLTAGE X POWER FACTOR ( X 1.732 for 3 phase ).
ACTIVE LOAD CURRENT SHARING, is controlled by the ENGINE GOVERNORS. SPEED 1560 RPM
0%
1500 RPM 0%
4.0% 100%
A MECHANICAL ENGINE GOVERNOR REQUIRES A MINIMUM OF 4% SPEED DROOP IN ORDER TO SHARE THE ACTIVE CURRENT (KW), WHEN IN PARALLEL.
PRODUCT TRAINING
CB1
BUS-BAR
LOAD
ENGINE 2/ 500 H.P
MCB
CB2
EXAMPLE : Two Generator Sets are required to run in parallel, both sets have equal size 500 H.P Engines, with mechanical ENGINE GOVERNORS. How will ENGINE 1 and 2 share the load AUTOMATICALLY, throughout all load variations, from NO LOAD to FULL LOAD ?
PRODUCT TRAINING
A.C Generator
Engine
EXAMPLE : In this analogy the truck ENGINE represents the GENSET DIESEL ENGINE, and the TRUCK represents the GENERATOR.
PRODUCT TRAINING
LOAD
LOAD
EXAMPLE : In this analogy the truck ENGINE represents the GENSET DIESEL ENGINE, and the TRUCK represents the GENERATOR.
As with a Genset, the truck engine speed is FIXED, at a constant speed ie.,1500 RPM.
When the truck is UNLOADED, the engine is powering the LOSSES only.
When the truck is LOADED, the engine must provide extra power, and the truck speed will fall (for example 4% SPEED DROOP), because the ENGINE GOVERNOR is fixed at constant speed.
What will happen if the trucks are NOW JOINED SOLIDLY TOGETHER??
PRODUCT TRAINING
LOAD
LOAD
The trucks are now JOINED TOGETHER, similar to two GENERATOR SETS when they are in PARALLEL.
How will the engines SHARE THE LOAD in the following situations ?...
1) Both ENGINES have SIMILAR LOAD CHARACTERISTICS from no load to full load ?
ANSWER - THEY WILL AUTOMATICALLY SHARE THE LOAD - EQUALLY
PRODUCT TRAINING
LOAD
LOAD
2) THE TRUCK IN FRONT HAS A STRONGER ENGINE THAN THE ONE AT THE BACK.?
ANSWER- THE FRONT ENGINE WILL TAKE LOAD AWAY FROM THE REAR ENGINE.
PRODUCT TRAINING
LOAD
3) The TRUCK AT THE BACK develops an ENGINE FAULT, and LOOSES POWER ?
ANSWER - THE FRONT TRUCK TAKES ALL OF THE LOAD, AND MOTORS MOTORS THE REAR TRUCK.
PRODUCT TRAINING
1500 RPM
ENGINE SPEED
0% 50% 100% PERCENTAGE LOAD 50% 0%
When BOTH Engines have similar GOVERNOR CHARACTERISTICS, they will share the kW load in parallel, AUTOMATICALLY, from NO LOAD to FULL LOAD.
When the engines have DIFFERENT governor characteristics, (as single running engines), load sharing will become UNEQUAL as kW load is INCREASED. In above example ENGINE 2 is the STRONGER ENGINE
PRODUCT TRAINING
CB1
ENGINE 2/ 500 H.P
EXAMPLE: Two different sizes of Generator Sets are required to run in parallel, Set 1 has a 50 H.P ENGINE, set 2 has a 500 H.P ENGINE. How will ENGINE 1 know that it must take 10% of the total kW load, AUTOMATICALLY, from NO LOAD to FULL LOAD ?
PRODUCT TRAINING
1500 RPM
ENGINE SPEED
0%
37 kW
50% 100% PERCENTAGE LOAD
370 kW
50% 0%
When BOTH Engines have similar GOVERNOR CHARACTERISTICS, they will PROPORTIONALLY share the kW load, AUTOMATICALLY, from NO LOAD to FULL LOAD. ENGINE 1 should AUTOMATICALLY take 10% of the load throughout all load changes.
PRODUCT TRAINING
CB1
BUS-BAR
GEN 2
ACTIVE CURRENT
Example : Engine 1 (50HP) develops a fault, which causes it to loose speed & power. What will happen if Engine 1 is running in parallel with Engine 2? Answer; Engine 2 will be supplying ALL OF THE LOAD CURRENT, and feeding back ACTIVE CURRENT (kWATTS) INTO GEN 1. GEN 1 has now become a MOTOR, DRIVING ENGINE 1. This is REVERSE POWER, and can severely DAMAGE the ENGINES.
PRODUCT TRAINING
MOTOR GEN 1
ENGINE 2, 500 H.P
CB1
BUS-BAR
GEN 2
ACTIVE CURRENT
REVERSE POWER can occur :1. NO LOAD - following synchronisation, if the INCOMING Engine speed is lower than the BUS BAR speed/frequency. 2. ON LOAD - if a FAULT occurs on one of the Engines, causing it to LOOSE POWER, or if the Governor is INCORRECTLY ADJUSTED relative to the other Generators. The Generator should be DISCONNECTED from the system to avoid damage. THIS IS ACHIEVED WITH REVERSE POWER PROTECTION
PRODUCT TRAINING
CB1
BUS-BAR
ISOCHRONOUS GOVERNOR
LOAD
kW FEEDBACK
How can kW Load sharing be achieved WITHOUT SPEED DROOP?, i.e., constant speed from no load to full load?
Answer : The Engines must be fitted with ISOCHRONOUS ELECTRONIC GOVERNORS. kW LOAD SHARING (kW), is achieved by GOVERNOR CONTROL from a kW feedback signal, which automatically controls the kW LOAD SHARING.
PRODUCT TRAINING
PRODUCT TRAINING