TECHNO CRAFTS & SOLUTIONS

Technical Note
on
Synchronizing Panel

2nd Floor, Plot No.49 Patel Nagar , Cantonment ,Varanasi 221002(U.P.) India
Contact No. : 0542-2500156
Email: tcsvns@gmail.com
S.No. Content
1 What is DG Synchronizing?
2 Sequence of operation
3 DG Set synchronizing Panels
4 Application of parallel Operation
5 Advantage of parallel Operation
6 Type of Synchronizing Panel
7 Manual Synchronization
8 Auto Synchronization
9 PLC based DG synchronization
10 Engine Protection
11 Alternator Protection
12 Feature of PLC
13 Technical Specification
 DG Synchronizing

DG Synchronizing System to be used to power saving and Start and Stop DG as per required
load in auto AMF function. From this system we can save fuel consumption of DG, wastage
of power, DG protection, auto load sharing. On AGC controller screen we can see the status of
system as below.

DG power, total run hour.

DG voltage, current, frequency.
DG load
BUS Voltage, Frequency
Alarms.
SLD status with led indication

If voltage, frequency, Phase sequence/Phase angle, of both DG set is same & all the
required data is ok then Controller will start DG otherwise it will not start.
DG Synchronizing Panel System to be Start DG as per required load. Basically it
can be operated By Auto Mode and Manual Mode. As per required Load we can
change Consumption mode to 2nd DG will be start automatically and start load
sharing with already running 1st DG.

Auto Mains Failure (AMF): Auto mains failure means disconnecting the load from the
utility mains when the supply fails, automatic powering up of the DG set and feeding
the load from the DGs and vice-versa.
Load Dependent Start/Stop: Load depended Start/Stop is a functionality available in the
DG Controller, wherein the controller will decide the number of DGs to be continued
in service based on the present load in the system. If the load on the bus decreases below
the set value in the controller, the controller issues stop command to highest run hour
DG and vice-versa.
DG Synchronization Controller: It is a multi-functional programmable controller
used to control, monitor, and synchronize DGs. It also has functions for the protection
of engine and alternator. Each DG requires one controller for its operation. DG Sync.
Controller will have input terminals for accepting the voltage, current inputs from the
alternator and bus. Programmable discrete inputs of the DG Sync. Controller will be
provided with the feedback from generator circuit breaker, feedback from protective
relays, neutral isolating contactor, DG instrumentation sensors etc. for logical
functioning. Programmable output relays of the controller will be used for DG
Start/Stop, GCB Open/Close and Emergency Stop etc. Also, the controller will have
analog output ports for voltage/speed bias signals etc. Leading controllers available in
the market are from Woodward, DIEF, Deep Sea, Cummins PCC, SICES etc.

CAN Bus : Controller Area Network is a widely used network communication

protocol used for the communication of machines and controllers. All the DG Sync.
Controllers in a system are communicating with each other through CAN bus, which
is typically a two-wire communication network. Now a days, most of the diesel
engines have electronic control circuitry with a CAN communication interface, allows
the DG Sync. Controller to communicate with engine as well.
 Voltage Bias: Voltage bias signal is the voltage signal given to the alternator's
automatic voltage regulator (AVR) for adjusting the terminal voltage in order to
match it with the other DG's voltage during synchronization process. It normally
varies between +/-3 V depending on the manufacturer.
Speed Bias: Speed bias signal is the voltage signal given to the engine speed
governor for adjusting the speed of the engine in order to match the frequency with
the other DG's frequency. It normally varies between +/-5 V depending on the
manufacturer. Now a days, the electronic DGs come with CAN communication port
through which the DG controller can communicate with the engine, which eliminate
the need of separate speed bias signal, Start/Stop command and instrumentation
cables from individual sensors, safety switches etc. to run from DG to the DG Sync.
Controller
Neutral Isolating Contactor (NIC) : Contactor used in the neutral circuit of DG to
isolate/connect the neutral during the synchronization process

Following devices are very much essential for establishing synchronism.

Electrically Operated ACBs for the Utility and DG Incomer feeders with under volt
coil, closing coil and shunt coil
Line Voltage Monitor
DG Sync. Controller
Current transformers in the alternator circuit and voltage inputs from alternator and
bus circuits
Basic electrical protective relays for the protection of alternator like Reverse/Reverse
reactive power relay, Earth fault relay, restricted earth fault relay/Differential
protection relay etc.
Temperature scanner for monitoring winding and bearing temperatures of the DG
(Optional based on the size of the rating of DG)
Battery charger circuit for DG battery
Instrumentation circuitry from DG to DG control panel for voltage bias, speed bias,
DG Start/Stop, RTD & BTD connection, High lube oil pressure, Oil temperature, Fuel
levels, Coolant temperature sensor, DC supply from battery charger to battery

Sequence of Operation:

For ease of understanding, we are discussing only about 2 nos. of DG sets syncing into a
common bus in AMF and Load dependent Start/Stop Mode.

Upon failure of the utility supply, the line voltage monitor gives feedback to all DG Sync.
Controllers. After preset time delay, the DG Sync. Controller gives Start command to
respective DG's starting circuit. Both the DGs will be started and upon healthy supply
feedback from DG (Rated Voltage and Frequency), the Controller issues close command to
first healthy DG's incoming breaker to close to the de-energized bus. This DG will be treated
as Master DG. Second DG breaker will be closed to the bus after matching the voltage and
frequency, upon getting close command from the respective controller. This DG will be
called Slave DG.
Controller keeps on watching the load in the system and tries to equalize the active and
reactive load on both the DGs equally by adjusting the engine speed governor and AVR. Both
these two DGs will run in synchronism for the pre-defined time sets in the controller. After
the pre-defined time is elapsed, the controller start initiates the load dependent Start/Stop
functionality.

If the total load on the bus goes less than the pre-defined value (Say 70% of DG Capacity)
sets in the controller, least run hour DG will run continuously, and the other DG's load will be
transferred to the previous one by the controller. After ensuring the transfer of whole load,
controller issue open command to second DG's breaker and accordingly the same will be
opened. Finally, second DG will be given stop command after running it for pre-defined
cooling period (Normally 3-5 Minutes). During the cooling period, if the load on the bus goes
high value set in the controller (Say >90%), the second DG will again come online after
satisfying the pre-requisite condition for synchronization as explained earlier.

When the utility supply is resumed, the LVM gives the feedback to the controller and the DG
breaker will be allowed to open after pre-defined time set in the controller (Say 15 Seconds).
After opening of the DG breakers, the EB breaker will be allowed to close automatically
through the electrical interlocking circuitry.

The whole process will complete within 15-30 seconds based on the number of DG sets and
the response time of engine.

At any point of time, if there is any internal or external fault in the system, the DG controller
will issue stop command to DG Set thereby shutdown the system.

While talking about the DG Synchronsiation, the need and working of neutral isolating
contactor cannot be unspoken.

Role of Neutral Isolating Contactor in DG Synchronisation:

When the alternators are paralleled, there always exists a small difference in the voltage
generated (Even though the RMS Voltages remains same) which will be different at different
points in time, this will cause a circulating current to flow between the machines. This
circulating current will be like a third harmonic current in nature, circulating through the
neutral circuit, will cause heating effects in the alternators and hence the effective loading
capacity of the alternators would be reduced.

Above situation could be eliminated by providing neutral isolating contactor (NIC) for all
DGs and connect only one NIC to bus at a time. The neutral of all the DGs are interconnected
in such a way that the neutral isolating contactor of only the highest capacity DG/Master DG
will be connected to the bus. NICs are also interlocked with the DG breakers and sequenced
in such manner that the NIC will be closed first followed by breaker. Also, reverse sequence
will be applied while opening the breaker. i e. breaker will be allowed to open first followed
by NIC. Arrangement will also made in the circuitry that in case the NIC of Master DG is
opened/damaged due to any reason, immediately the NIC of slave DG will come online and if
the same is not happened DG breaker is allowed to trip the circuit, as the system cannot be
made operational without neutral.
Though the article explains the DG synchronsing process in a simple way, the actual
operation and circuitry is much more complicated due to the presence of logical circuitry
using contactors and timers for different protective interlocking, protective and metering
circuits etc. Hence careful and diligent reasoning is essential for understanding the whole
system.
Theme & System Advantages

KIRLOSKAR OIL ENGINES LIMITED 1

 D G Sets Synchronizing Panels

Synchronization is the process of running two or more DG

sets in parallel on common bursar, while matching the
characteristics of each system as closely as possible.

This is accomplished by minimizing the phase-angle

difference, frequency difference, voltage difference &
matching phase sequence between the two systems.
 Applications of Parallel operations

• Synchronizing panels are widely used in various fields

where heavy power inputs are required like:

• Telecom Sector Processing plants

• Engineering units Hospitals

• Hotels Offices

• Institutions Etc

3
Advantages of DG sets in Parallel operations

• Continuous back up of power supply

• Without failure of power supply, maintenance of dg set can

be done.

• As per load condition required no. of dg sets can be

operated.

• Fuel saving

• In case, failure of one set, power can be drawn

from other sets without any trouble.
 Types of Synchronizing Panels

• Manual synchronizing

• Automatic synchronizing

5
Manual Synchronizing- Types of Synchronizing panels

• This is done by the trained operator by comparing the

values for voltage, frequency & phase angle of bus bar &
dg to be synchronized using under mentioned
instruments mounted & wired on panel board:
Double voltmeter Double frequency meter

Syncroscope Lamps

Potentiometer Volt meter

Ampere meter Power factor meter

Killo-Watt meter
Manual Synchronizing- Types of Synchronizing panels

After synchronizing & closing of breakers, two kind of load

sharing are required :

Active load sharing :

This is attained by increasing or decreasing rpm of
engine using potentiometer on panel board

Reactive load sharing :

This is attained by increasing or decreasing voltage of
alternator using potentiometer on panel board

Cont. …..
 Protections relay

• Check sync relay

• Reverse power relay

• Earth fault relay

 Auto Synchronizing Panels

• For automatic synchronizing pre programmed

microprocessor based relays or PLC are used and the
whole process is completed step by step automatically
without any manual involvement.
• Kirloskar Engines have electronic governor with the provision of manual setting
of droop with simple tool. (in other make laptop with software is required on site for any
setting in governor, which may cause unnecessary delay from service point of view.)

• All synchronizing panels can be manufactured with the combination of Micro

processor based relay e.g. Woodward or PLC e.g. Allen Bradley or Siemens.

• Panel for synchronization of 4-6 nos. of dg set (250kva to 600kva) with AMF logic
can be supplied as per customer requirement i.e. automatic or manual.
PLC based DG Synchronization System
 Isochronous Load Sharing

Unit A Unit B
1000 KW 800 KW

50 Hz 50 Hz

0 25 50 75 100 % 0 25 50 75 100 %
( 500 KW ) ( 400 KW )
 Bump less Load Transfer

TOTAL PLANT LOAD

Gen 1
Gen 2

ISO LOAD
LOAD SHARING
Unload Gen 1 Initiated

Gen 2 Breaker
Opens ( Gen 1)

 Gen1 Breaker
Gen 2 Closes ( Gen 2 ) TIME
 Kirloskar Green Offers

• Automatic DG Synchronization
• Automatic Isochronous Load Sharing
• Bump less Load Transfer
• AMF Function
• Inbuilt Engine Protections
• Inbuilt Alternator Protections
• Load Management System
• Auxiliary Control
 Synchronizing

• Phase Match Synchronizing (up to 2* phase error)

• Digital Signal Processing to reduce harmonics
• Voltage Matching (Up to 0.1%)
• Multiple Reclosing Attempts
• Safe Dead Bus closing logic
• Three Modes of operation (Run/Check/Permissive)
• Capable of Grid & DG Synchronization
• Manual Synchronization Capability
 Load sharing

• Isochronous Proportional Load Sharing

• Active as well as Reactive Load Sharing
• Load Ramping
• Adjustable Loading/Unloading ramps
• Power Factor Control
 Engine Protections

• High/Low Coolant Temperature

• High/Low Lube Oil Pressure
• Over Speed
• Start Failure
• Cool Down Timer
• Idle/Rated Control
 Alternator Protections

• Over/Under Voltage
• Over/Under Frequency
• Reverse Power (Inverse Time Delay)
• Reverse KVAR
• Over Current (Inverse Time Delay)
• Load Surge
• Speed/Frequency Mismatch
 Automatic Sequencing

Master Slave Slave Slave

Priority 1 Priority 2 Priority 3 Priority 4

• Sequencing Uses Master - Slave Configuration.

• Each Unit in the system has an assigned Priority.
• Master (Highest Priority) automatically sequences units
on or off line as determined by system load.
• Higher priority units are sequenced on in order of their
priority; taken off in reverse of priority.
• Online Changing of Priority
 Features of PLC

• PLC has a high performance distributed architecture that

reduces costs and risks.
• PLC’s powerful open communications makes it easy to
share information
• PLC is a good value - large PLC power in a smaller
package
• PLC is easy to maintain
• PLC can save time, money, and reduce project risk with
highly integrated intelligent functions.
Memory - flexible and easy to maintain

• Easy to expand
– PCMCIA cards can be easily added to the Type I
PCMCIA slot on the front of the CPU, minimizing
maintenance time.
• Backup memory
– Program, constants, module parameters
– Easy field updates
 DIRECT INTERFACE

Electronic
Governor

 Direct interface to Electronic Governors

– No relay, contact, MOP in the circuit

 Faster Response
 High Reliability
 Adjustable Load/Unload ramps
 Load Sharing

• Isochronous Load Sharing

• %age based Loading of DG sets
• Better utilization of DG sets
• No Jerks on Supply System due to Bump less Load
Transfer
• Smooth Loading & Unloading
• Very fast & reliable synchronization
• Constant frequency over the entire range
 PLC is Easy to Maintain

plug ‘n play (no

switches)
diagnostic LEDs

electronic keying
broken wire detection,
terminal block detection

protection - short circuit, Hot Swap

overload, preactuator
voltage, surge protection
removable
coding of
terminal blocks
modules and
terminal blocks
 Other Advantages

• Specific Design for the Power Generation market

• Flexibility: Easy addition & deletion of DG Sets
• Modular: Each DG has a dedicated control
• Standard Hardware & Software
• Component Integration: Cost & space saving
• Saving in space/field wiring
• 24 V DC supply from engine battery
• Inbuilt Generator Protection
TECHNICAL SPECIFICATION OF DG SYNC. PANEL

DG SYNC. PANEL Nos.

1
ACB 630A 4P 35KA EDO 3
2 COMMUNICATION MODULE-ACB 2500A 2
3 PROTECTION RELEASE 2
4 MFM-RS 485 2
5 CT 630/5A 15VA CL-1 6
6 NUMERIC RELAY 2
7 CT 630/5A CL 10P5 6
8 DG. VOLTMETER 2
9 VSS 2
10 DG. AMMETER 2
11 ASS 2
12 CT 630/5A 6
13 RYB INDICATOR 6
14 MCB 6A 1P 10KA 6
15 RGA INDICATOR 6
16 MCB 6A 1P 10KA 2
17
ACB AUX. CONTACT 630A 2
18 PUSH BUTTON-START/STOP 4
19 REVERSE POWER RELAY 2
20 PHASE SEQUENCE+VOLTAGE MONIT. RELAY 2
3PH.
21 EARTH FAULT RELAY 2
22 RESTRICTED EARTH FAULT RELAY 2
23 MASTER TRIP RELAY 2
24 AL BUSBAR 1200A 1
25 Synchronization Relay 1
26 Auto Manual Selector Switch 1
27 PLC With HMI 7 Inch Color TFT 1