Engine Generator Paralleling

Concepts
Gen.
#1

Presenter:

Gen.
#2

Gen.
#3

Gen.
#4

Gen.
#5

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

to Utility Grid Connection

RUNNINGGenerator
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

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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

RUNNINGParalleling
HEADLINEGenerators for Capacity

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

500 kW

GENERATOR #1

52-G2

500 kW

GENERATOR #2

500 kW
+ 500 kW
1000 kW

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

500 kW

GENERATOR #1

52-G2

500 kW

GENERATOR #2

500 kW
+ 500 kW
1000 kW

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

Whyy not use a pparallelingg 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 ffor 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

PLC
Logic

Bi-Fuel
Controller

Load Share Module

(kW)

Voltage
Reg lator
Regulator

Load Sharing
(kVAR)

Integrated Solution
HMI

Protective
Relaying

Speed
p
Governor
Auto
Synchronizer

Digital
Communications

RUNNING
HEADLINE
Synchronization
Wave Form Alignment
Electrically locking two machines together
Voltages matched
Frequencies matched + Slip frequency offset
Phase angles matched

PHASE VOLTAGES
MATCHED

PHASE VOLTAGE
MISMATCH
VX

VY

PHASE ANGLE
MISMATCH

PHASE ANGLE
MISMATCHED

0
0

90

180

270

360

PHASE VOLTAGES MATCHED

PHASE ANGLES MATCHED

0
0

90

180

270

360

90

180

VY
VX

VX = V Y

SYNCHRONIZED

270

360

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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
Switchingg Utilizingg Contactor
Mounted on Generator

RUNNING HEADLINE
Electrical Interlock Stage 2

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

RUNNING HEADLINE
Load Sharing Power Balance

Gen

Gen

kVA

kVAR

kVA

kVAR

kW

kW

RUNNING HEADLINE
Load Sharing Protection

(+ kVAR)

Reverse
Reverse Power
Power

Normal Operation

+ kVAR

+ kVAR
- kW

- kVAR

+ kW

(+ kW)

- kVAR

Reverse Power
&

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
kVA INDUCTIVE
(LAG)

kVAR

ENGINE
GENERATOR

kVAR

A
kV

NET kVAR
(LAG)

Phase Angle
kW
kVA CAPACITIVE
(LEAD)

Isochronous Governors

Isochronous governors
What happens if two are connected together??

(0 - 100%)
Must be 0

Speed
Reference
(90 - 110%)

Throttle
Position

PID

Power
(kW)

Speed

Understanding Droop

(0 - 100%)
Must be 0

Speed
R f
Reference
(100 - 105%)

Throttle
Position

Power
(kW)

S d
Speed

PID
(0 - 100%)

Droop
(.05)

Load Sharing Control Circuit

RUNNING HEADLINE
Traditional load sharing
Isochronous load sharingg
Reactive Cross Current Compensation
Struggles with calibration, stability, electrical noise
SPEED ADJUST

SPEED ADJUST

52-G1

52-G2
PT

CT

AUTOMATIC
VOLTAGE
REGULATOR

AVR

GOVERNOR

ENGINE

GENERATOR #1

kW LOAD
SHARING
MODULE
CT

LOAD SHARING
LINES

FUEL (SPEED)
BIAS SIGNAL

kW
SENSO
OR

kW
SENSO
OR

PT

AUTOMATIC
VOLTAGE
REGULATOR

AVR

GOVERNOR

ENGINE

GENERATOR #2

kW LOAD
SHARING
MODULE

FUEL (SPEED)
BIAS SIGNAL

Droop Load Sharing

Speed droop graphical representation
Will two speed
p
droopp ggovernors share load?
What is the negative consequence?

Hz
63.0

SET S
PEED

61.5

SET S
PEED

60.0

SET S
PEED

58 5
58.5

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

RUNNING
CONDITION
AT TIME OF
PARALLELING

57.0

0%

GENERATOR LOAD

100%

kWe

RUNNINGTraditional
HEADLINE Control vs. Integrated

Traditional Approach

Integrated Approach
Simple
Reliable
R li bl
Single Source

2 wire start

RS485

Generator
Controller
Integrated
Parallel
Controller

Gov. Controller
Voltage Reg.

CPU

System
Controller

kW Share Module
kVAR Share Module
Generator
Controller
Gov. Controller

To Emergency
Distribution

Voltage Reg.
Analog Control Lines
Digital Control Lines
Sensing Lines
P
Power
Lines
Li

Integrated
Parallel
Controller

To Emergency
Distribution

RUNNING HEADLINEProtection

Synchronizing process
PT

25 sync check relay

52-G1

Real power system (governor & engine)

51G

25
51G

32
CT

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

Cabling & alternator

50 / 51 Overcurrent

81
O-U

27/59

40

46

25

50/51
(27)

24

32
CT

87G

Reactive power system (regulation &

excitation)

52-G2

50/51
(27)

32 reverse ppower
81 o/u frequency protection

PT

GENERATOR #1

87G

GENERATOR #2

81
O-U

27/59

40

46

24

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Normal.

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Utility failure.

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Generators start.

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

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

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
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

RUNNINGIntegrated
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

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

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

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Generator is restarted.

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
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

RUNNINGIntegrated
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

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Utility is re-energized.

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
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

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Generators cool down.

Emergency
Distribution Panel

Equipment
Transfer Switch

System
Controller
Generator 1

Generator 2

RUNNINGIntegrated
HEADLINE Sequence of Operation
Critical
Transfer Switch

Status:
Generators disconnect from system.
Generators shut down.
down

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

Reliability
Scalable
Cost
Footprint
Serviceability

52-G1
51G

PT

25

52-G2

50/51
(27)

51G

32
CT

81
O-U

27/59

40

46

25

50/51
(27)

24

32
CT

87G

GENERATOR #1

87G

GENERATOR #2

81
O-U

27/59

40

46

24

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 growthh
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
Parallelingg /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

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Capital Cost - Integrated
Generator
Control

PLC
Logic

Bi-Fuel
Controller

Load Share Module

((kW))

Voltage
Regulator

Load Sharing
(kVAR)

Integrated Solution
HMI

Protective
Relaying

Speed
Governor
Auto
Synchronizer

Digital
Communications

RUNNING HEADLINE

Footprint

Foot Print Size vs. Location

Flexibilityy
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 flexibilityy
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
Integrated
Scalability
Serviceability
Reliabilityy