In the name of Allah , the Beneficent, the Merciful.

AUTO SYNCHRONIZING AND AUTO

LOAD SHARING

Definition
Synchronizing, in its simplest form, is the process of electrically
connecting additional generators to an existing bus.
Before two or more A.C. supplies can be closed together in
parallel, the frequency, voltage and phase of the supplies must be
matched as closely together as possible. Collectively, frequency and
voltage matching are known as synchronization.

Necessity for Synchronizing

The necessity for synchronizing and parallel generator operation is
often based on the following.
1. The rated generating capacity of an existing system has been
exceeded by new load demands.
2. Enhanced reliability (multiple generating vs. single unit generating)
is to be considered.
3. Operating efficiency of generator sets is a valid concern

 There are five conditions that must be met before the

synchronization process takes place. The source (generator or subnetwork) must have equal line voltage, frequency, phase
sequence, phase angle, and waveform to that of the system to
which it is being synchronized.
Waveform and phase sequence are fixed by the construction of the
generator and its connections to the system.
The voltage, frequency and phase angle must be controlled each
time a generator is to be connected to a grid
Synchronization is achieved firstly by adjusting the engine speed
and generator voltage to get the frequency and voltage of the
generator closely matched to that of the bus / mains supply.
Then the phase angle of the supplies is monitored until it is within
an acceptable before the supplies can be closed together in parallel
Typically, a frequency difference (called slip frequency) of 0.1Hz, a
voltage difference of 5% and a phase angle of 5% will allow for
satisfactory paralleling of the supplies.

Voltage
Terminal voltage has two things,
Voltage level(Magnitude).
Voltage frequency( cycles per second).

A synchronous electrical machine (generator or motor) is intended

to be operated at a constant speed (synchronous speed). When the
generator rotor is rotated, the magnetic flux of the generator rotor
induces a voltage in the generator stator windings--called the
generator terminal voltage.
When the speed of the generator rotor is constant (or at rated) and
the excitation is constant, the generator terminal voltage will be
constant, or stable. The magnitude of the generator terminal
voltage is a function of the strength of the magnetic field of the
generator rotor--since the generator rotor is being rotated at a
constant speed: synchronous speed.

The exciter (AVR) controls the strength of the rotor magnetic

field, and the strength of the rotor magnetic field controls the
magnitude of the generator terminal voltage. (Again, we are
presuming the generator rotor is spinning at synchronous
speed, which is also the rated speed for the generator, for the
purposes of our discussion.)
Form above discussion it is stated that
Voltage level is control by AVR.

TYPES OF SYNCHRONIZING
Manual Synchronizing
Manual synchronizing is widely used on a variety of machines. The
basic manual synchronizing system includes synchronizing lights, a
synchroscope, metering, and a breaker control switch. With manual
synchronizing, the operator controls the speed and voltage of the
oncoming generator and closes the breaker at the proper time.
The chief advantages of manual synchronizing are system simplicity
and low cost. This method may be used with any type of generator
where an operator is available to monitor the power plant.

Manual With Permissive Relay

This method of synchronizing is manual synchronizing, with the
addition of a sync-check relay. The sync-check relay is provided to
back up the operators decision to close the generator breaker. In
other words, the sync-check device only allows breaker closure to
occur when the phase angle, frequency, and voltage are within
predetermined limits. The operator can close the breaker with
added confidence from knowing the synch check relay is doublechecking the breaker closure.

Automatic Synchronizing
With automatic synchronizing, the automatic synchronizer monitors
frequency, voltage and phase angle, provides correction signals for
voltage matching and frequency matching, and provides the
breaker closing output contact.

Auto Load Sharing

Sensing both active & reactive power will perform auto load sharing. The
percentage loading of a particular DG will be fed by MMI. This feature is
important when synchronization is done between new and old, or
between DGs of different ratings. New DG is normally has high loading
factor than a old DG. PLC will allow only predefined loading to all the DGs

Load Management System

Load management system is designed for auto start/ stop for the
slave DG sets as per the load requirement i.e. in case of running DG
sets being over load (more than 80%) then PLC will start the next
DG sets after a pre-defined time delay. After starting the DG set PLC
will take care the synchronization and proper load sharing as per DG
rating. In case running DG sets being under load (less than 60%)
then PLC will stop the one DG set after transferring the load on
another running DG sets

 If Single DG is running on load and total load is more than 80% of

running DG then PLC will start the 2nd DG after a pre-defined time
delay. Synchronization and load sharing shall be done by PLC
automatically.
If two DG`s are running on load and total load is more than 80% of
running DG`s then PLC will start the 3rd DG set after a pre-defined
time delay. Synchronization and load sharing shall be done by PLC
automatically.
If N DG set are running on load and total load is less than 70% of N1 DG set then PLC will trip the ACB/MCCB of last DG automatically
after a pre-defined time delay. Engine will stop after 3 minutes idle
running in auto mode.
Above process shall continue while running the system in auto
mode to achieve the maximum efficiency of DG set.

Master DG
PLC system will monitor the Grid Failure signal through under
voltage relay. As soon as GRID
supply fails, PLC will start master DG set and after getting the
proper voltage and frequency,
PLC will close the first neutral contactor and then DG incomer
MCCB automatically after
ensuring the T/F ACB is in trip condition.
When GRID supply gets restored PLC will issue an audio-visual
alarm after a pre-defined time
delay to operator attention. Change over will be done automatically
by PLC with proper
interlock i.e. PLC will first trip the DG sets incomer ACB/ MCCB then
transformer ACB shall
be switched-on automatically.

Slave DG:
Slave DG, start/ stop will be done as per Load Management system.
After starting the slave DG set, PLC will compare the Voltage,
Frequency and Phase angle between Synchronizing bus & reference
bus. After matching these parameters PLC will close the slave DG
ACB/ MCCB automatically. Load sharing will be also done by PLC
automatically.

SYSTEM FEATURES
The system is designed run in AUTO as well as in MANUAL mode. In
auto mode the system will run automatically with predefined
sequence and in manual mode all the operation will be done as per
the sequence will be defined by operator.
DGs will be started & stopped automatically as per the load
requirement on the main bus.
Selection of DGs for DG start stop automatically on sudden load
requirement.
Automatic synchronization of DG sets in Auto mode
Active & reactive Load sharing of each DG set
Automatic selection of Next DG as master after stopping / tripping
of master DG to close NGR circuit.

 Monitoring of electrical parameter of each DG, voltage, frequency,

reactive load, active load, energy produced, voltage error (%),
frequency error and phase angle error etc.
Status & control of outgoing breakers
Back up protection electrical / mechanical by time delayed tripping
of Dg sets.
Reverse power; reverse KVAR, under voltage, over voltage, under
frequency, over frequency, over current, low lube of oil pressure,
high cooling water pump, over speed etc.
Data acquisition system will be incorporated with the system for the
purpose of recording & display of all important & critical
parameters of the engine, alternator & system as such in totality.
Operation of the system will also be through operator interface
with graphics screen into PC Pentium computer.

 B checks alarm after each DG complete 300 hours of running for

proper maintenance.
Tripping of non-critical loads in the plant in case of under
frequency of bus both in isolation as well as synchronized mode.
Control of all auxiliary drive of DG sets will start stop automatically
with proper interlocks as per safety considerations.
PLC system will have provision to test the DG in auto mode without
closing the breaker to do the routine electrical / mechanical testing
of DG sets without interruption of power generation

MULTI SET COMMUNICATIONS (MSC) LINK

The Multi Set Communications (MSC) link in use with DSE
synchronizing and load sharing modules performs many functions
including load sharing and protection.
SYNCHRONISING
LOAD SHARING
o Active (kW)
o Reactive (kVAr

START/STOP ON LOAD DEMAND

Starting sequence
o Run Priority
o Balance engine hours

MSC ALARMS
MSC ID ALARM
MSC DATA ERROR
MSC FAILURE

ADVANTAGES OF AUTO SYNCHRONISING

Changing of logic is 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.
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.
Because of KW dependent load sharing, optimum utilization of D.G.
sets are possible. This increases D.G. sets efficiency & saves lot of
fuel.
Use of PLC reduces no. of relays, contactors, wiring etc. This
reduces fault points & increases the MTBF of the system.
All the future changes / modifications can be easily made through
software only.

Automatic Changeover
Mains source failure
Automatic Changeover Switch panel is designed to monitor & to
start Generator control panel automatically when the mains source
fails partially or fully. The control panel provides a potential-free
contact output & provides signal to the remote generator control
panel to enable automatic start of the generator.
On sensing that the generator is running at correct output the
changeover switch changes over from the mains position to
generator position, thereby transferring the site load.

When Mains restores

L.V.M. checks the mains for its healthiness, the generator is then
disconnected from the load and automatic changeover back to the
mains source takes place. Load is now connected to the mains.
Gen set is then run for about 5 minutes time set, on no load and it
is stopped automatically

AMF Panel
AMF Control panel is designed to monitor & to start Generator
automatically when the mains source fails partially or fully.
When mains fail, then it is sensed by Line Voltage Monitor (L.V.M.)
and three starting pulses are given to Gen set.
If Genset does not start within three attempts, then STARTING
FAILURE alarm is sounded and stop signal is given to Genset to stop
it fully & no start signals are given further.
When Genset starts successfully, it builds up the rated voltage and
Genset contactor/breaker is closed automatically. The load then is
switched on / transferred to the Genset.
When Mains restores, which is checked by L.V.M. for its healthiness,
the generator is then disconnected from the load and automatic
transfer back to the mains source takes place. Load is now
connected to the mains.

 Genset is then run for about 5 minutes time set, on no load and it is
stopped automatically.
Safeties like L.L.O.P., H.W.T. and over speed are operative when the
Genset is running. For any of the above faults, Genset stops
immediately.
Automatic function can be totally by-passed and Genset can be
started-stopped in manual mode also.

Indication for the following

Low oil press

High room temp.

Over speed
Fail to start
DC battery REV POLARITY
Engine hours run counter
RPM
Frequency
Voltage
Current
Engine temperature

Shutdown Protections

Low oil press

High room temp
Over speed
Fail to start
Under speed
Over current
Blower failure
Earth fault

PANEL ACCESSORIES

1 Voltmeter
3- Ammeter
1- Freq.
RPM meter
Fail to start
1- Battery voltmeter
1-Engine hours run counter
1- Oil press. Gauge
1- Engine temp. gauge
3- C.T. above 100 A

 1- voltmeter sel.
1- Electronic generator control module fully programmable
with Control key switch Off / Run / Start (OPTIONAL)
1- MCB / MCCB
4- AC and DC fuses
1- Control terminals
1- Neutral terminal
1- Set of AV mounts (OPTIONAL)
2- 20/30 amp rated relays for fuel and start solenoids