Engine Generator Paralleling Concepts

Gen. #1 Gen. #2 Gen. #3 Gen. #4 Gen. #5

Presenter:

Daniel Barbersek Power Solutions Manager Generac Power Systems, Inc.

What Topics Will Be Covered RUNNING HEADLINE

Upon completion of this presentation, participants will be able to describe the basic concepts and implementation approaches to parallel generator operation including both Traditional and todays Integrated techniques. They will also be able to identify the advantages of integrated parallel systems over single generator applications. Specifically they will be able to:
Describe the concept of creating larger power systems using paralleled generators. Describe generator to grid and generator to generator configurations. Describe the differences between the traditional and integrated approach to generator paralleling. Describe the electrical requirements needed for proper operation of parallel operation. List and describe the functional and economic limitations of Traditional generator paralleling. List and describe the key benefits of the Integrated approach to generator paralleling. List and describe the key benefits of an Integrated parallel system over a Single g generator.

RUNNING HEADLINE What is paralleling?

Generator to Utility (Grid Inter Inter-Connected) Connected) Generator to Generator

Generator to Utility Grid Connection RUNNING HEADLINE

Electrically connected to the utility grid Energy management

Emissions (natural gas engines) Spark Spread (cost feasibility) Utility barriers (standby charges, ratchets, grid interconnect) EPA Regulated Tier 4 Required Engines if utilizing diesel

Momentary Grid Paralleling RUNNING HEADLINE

Make-before-break transfers
CTTS (less than 100 msec) Soft-load Closed transition (few seconds) Synchronize the generator to the utility momentarily Exercise with load No outage on retransfer Circuit Breaker or Contactor Styles available

Generator

Utility

Load

Paralleling Generators for Capacity RUNNING HEADLINE

What is a paralleling system?

Two or more generators are electrically coupled together using special equipment to form a larger capacity power source.

52-G1

52-G2

500 kW + 500 kW 1000 kW

500 kW

500 kW

GENERATOR #1

GENERATOR #2

Paralleling Generators for Redundancy RUNNING HEADLINE

N+1
The customers load requirements would be 500kW even though the system can create 1000kW. This leaves the system the ability to maintain the critical load in the event that one of the generators is taken off-line.

52-G1

52-G2

500 kW + 500 kW 1000 kW

500 kW

500 kW

GENERATOR #1

GENERATOR #2

RUNNING HEADLINE Paralleling Generators

Why use a paralleling system? Reliability Accepted market reliability for single engine is 98-99% Redundant systems offer multiple nines reliable for the critical loads N+1 reliability (99.96 to 99.99%) N+2 reliability (99.9992 to 99.9999%) Scalable Ability to expand as your clients needs grow Dont over build preserve capital Serviceable Protect the critical loads while servicing the generator(s)

RUNNING HEADLINE Generator to Generator Paralleling

Why y not use a p paralleling g system? y Traditional implementations have limitations Cost (capital, installation, commissioning) Complexity Space

RUNNING HEADLINE What is Required

to Parallel Generators

S h i i Synchronizing Switching Device Load Sharing Protection

RUNNING HEADLINE Getting Started - Preliminary

Prior to Synchronizing
Electronic governor -- load sharing Electronic El i voltage l regulator l w/ / paralleling ll li capability Identical internal alternator winding pitch (i.e. (i e 2/3, 4/5, etc). Same number of phases Same phase to phase voltage Same phase rotation

RUNNING HEADLINE Synchronization

K Elements Key El t f for paralleling ll li generators t Light goes dim Push it in!

RUNNING HEADLINE Synchronizing Controls

Waveform Alignment
Engine Speed needs to be controlled Alternator Voltage needs to be adjusted

Generator Control Bi-Fuel Controller Voltage Reg lator Regulator

PLC Logic Load Share Module (kW)

Integrated Solution HMI

Load Sharing (kVAR)

Speed p Governor Auto Synchronizer Digital Communications

Protective Relaying

RUNNING HEADLINE Synchronization Wave Form Alignment

Electrically locking two machines together Voltages matched Frequencies matched + Slip frequency offset Phase angles matched

PHASE VOLTAGE MISMATCH VX PHASE ANGLE MISMATCH

PHASE VOLTAGES MATCHED VY PHASE ANGLE MISMATCHED

PHASE VOLTAGES MATCHED PHASE ANGLES MATCHED

0 0 90 180 270 360

0 0 90 180 270 360

0 0 90 180 270 360

VY VX VX = V Y

SYNCHRONIZED

RUNNING HEADLINE Synchronizing Stage 1

Voltage level and alignment has been satisfied

RUNNING HEADLINE Device Switching

Traditional Switching Utilizing Circuit Breakers

RUNNING HEADLINE Integrated Switching

Integrated g Switching g Utilizing g Contactor Mounted on Generator

RUNNING HEADLINE Electrical Interlock Stage 2

Generators are now electrically interlocked There is not enough force provided by y the prime p mover to break the generators g apart p

RUNNING HEADLINE Load Sharing Power Balance

Gen

Gen

kVA kW

kVAR

kVA kW

kVAR

RUNNING HEADLINE Load Sharing Protection

(+ kVAR)

Reverse Reverse Power Power

Normal Operation

+ kVAR - kW - kVAR
Reverse Power
&

+ kVAR

+ kW - kVAR

(+ kW)

Under-excited

Under-excited

Load Sharing Load Sharing (Matching) Real Power (kW) Isochronous load sharing or speed droop Reactive Power (kVAR) Reactive cross current or voltage droop
kW kVAR kVA INDUCTIVE (LAG) NET kVAR (LAG) kVAR kVA CAPACITIVE (LEAD)

A kV

ENGINE GENERATOR
Phase Angle kW

Isochronous Governors

Isochronous governors What happens if two are connected together??

(0 - 100%) Must be 0

Throttle Position
PID

Power (kW)

Speed

Speed Reference
(90 - 110%)

Understanding Droop

(0 - 100%) Must be 0

Throttle Position
PID

Power (kW)

S d Speed

Speed R f Reference
(100 - 105%)

(0 - 100%)

Droop
(.05)

Load Sharing Control Circuit RUNNING HEADLINE Traditional load sharing Isochronous load sharing g Reactive Cross Current Compensation Struggles with calibration, stability, electrical noise
SPEED ADJUST 52-G1
PT

SPEED ADJUST 52-G2

PT

kW SENSO OR

CT

LOAD SHARING LINES

CT

AUTOMATIC VOLTAGE REGULATOR

GOVERNOR

FUEL (SPEED) BIAS SIGNAL

kW SENSO OR

kW LOAD SHARING MODULE

kW LOAD SHARING MODULE

AUTOMATIC VOLTAGE REGULATOR

GOVERNOR

FUEL (SPEED) BIAS SIGNAL

AVR

ENGINE

AVR

ENGINE

GENERATOR #1

GENERATOR #2

Droop Load Sharing Speed droop graphical representation Will two speed p droop pg governors share load? What is the negative consequence?

Hz
63.0 61.5 60.0 58 5 58.5 57.0
SET S PEED SET S PEED SET S PEED

FIXED UTILITY AND BUS FREQUENCY DIESEL GENERATOR 5% DROOP GOVERNOR - VARIOUS SET SPEEDS

RUNNING CONDITION AT TIME OF PARALLELING

0%

GENERATOR LOAD

100%

kWe

RUNNINGTraditional HEADLINE Control vs. Integrated

Traditional Approach
2 wire start Generator Controller Gov. Controller Voltage Reg. CPU kW Share Module kVAR Share Module Generator Controller Gov. Controller Voltage Reg. Analog Control Lines Digital Control Lines Sensing Lines P Power Lines Li To Emergency Distribution

Integrated Approach
Simple Reliable R li bl Single Source
RS485 Integrated Parallel Controller

System Controller

Integrated Parallel Controller

To Emergency Distribution

RUNNING HEADLINE Protection

Synchronizing process
25 sync check relay
52-G1 PT PT 25 51G 52-G2
50/51 (27)

25

Real power system (governor & engine)

32 reverse p power 81 o/u frequency protection

51G

50/51 (27)

81 O-U

27/59

24

81 O-U

27/59

24

32 CT 87G

40

46 CT

32

40

46

87G

Reactive power system (regulation & excitation)

27 / 59 voltage protection 24 over excitation & volts/hz

GENERATOR #1

GENERATOR #2

Cabling & alternator

50 / 51 Overcurrent

RUNNING HEADLINE Sequence of Operation Integrated

Critical Transfer Switch

Status: Normal.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Utility failure.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Generators start.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Status: First generator at rated output. Energizes g the emergency g y distribution panel. p
Critical Transfer Switch

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Picking up the critical load in 10 seconds.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Equipment load transfers to the generators.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Status: If a generator is out of service, it separates from the system. y Non-critical load is shed.
Critical Transfer Switch

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Generator is restarted.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Generator parallels to the system.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Equipment load is re-energized.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Utility is re-energized.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Load is transferred back to utility.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Critical Transfer Switch

Status: Generators cool down.

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

Integrated RUNNING HEADLINE Sequence of Operation

Status: Generators disconnect from system. Generators shut down. down
Critical Transfer Switch

Emergency Distribution Panel

Equipment
Transfer Switch

System Controller
Generator 1 Generator 2

RUNNING HEADLINE Paralleling Advantages

Paralleling Vs. Si l G Signal Generator t

PT PT

Reliability Scalable Cost Footprint Serviceability

52-G1 51G
50/51 (27)

25 51G

52-G2
50/51 (27)

25

81 O-U

27/59

24

81 O-U

27/59

24

32 CT 87G

40

46 CT

32

40

46

87G

GENERATOR #1

GENERATOR #2

RUNNING HEADLINEReliability
Accepted market reliability for single unit 98 to 99% (multiple third party references) Integrated paralleling adds redundancy Typical load factors M Minimal l load l d shedding h dd / management Results in redundancy without increasing generator capacity N+1 reliability (99.96 (99 96 to 99.99%) 99 99%) N+2 reliability (99.9992 to 99.9999%)

Vs.

RUNNING HEADLINE Scalability

Start with a single generator Pl Planned d growth h Unanticipated growth Lower initial investment Budget / capital constraints Protection against uncertainty
Single generator implementations offers no cost effective expansion capabilities This solution typically uses sizing safety factors to protect against uncertainty and load growth.

RUNNING HEADLINE Cost of Installation/Ownership

Integrated g Paralleling g /Single g Generators Cost

Capital cost
Optimizing market engine pricing (high volume engines)

Installation cost
Same amps, same distance Potential for smaller cabling (NEC 800 amp breaker roundup rule) Potential crane reduction (40 ton vs. 80 ton) Pad thickness reduction (6 vs. 10-12)

Maintenance cost
More manageable fluids Comparable consumables Ask for PM quotations for both options

RUNNING HEADLINE Capital Cost - Traditional

RUNNING HEADLINE Capital Cost - Integrated

Generator Control Bi-Fuel Controller Voltage Regulator Integrated Solution HMI Protective Relaying PLC Logic Load Share Module (kW) ( )

Load Sharing (kVAR)

Speed Governor Auto Synchronizer Digital Communications

RUNNING HEADLINE

Footprint

Foot Print Size vs. Location Flexibility y Foot print examples 1000kW (26.1 x 8.4) 2 x 500kW (19.2 (19 2 x 13.5 13 5) ) 1500 kW (33.3 x 8.4) 2 x 750 kW (16 (16.9 9 x 16 16.5) 5) Location flexibility y Various layouts Units can be separated Parking garages Rooftops

RUNNING HEADLINEServiceability

Single generator implementations Limited to no protection while servicing Can your critical loads go without protection? g Oil & coolant changes Belts, hoses, batteries Load bank connection Minor repairs Major repairs At what point do you bring in a rental? Change-over time Paralleled implementations provide protection during servicing

RUNNING HEADLINE Conclusion

Traditional Integrated Scalability Serviceability Reliability y