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I. INTRODUCTION
HE purpose of a turbogenerator in a process plant is to
T produce power, save energy cost, and minimize power
outages during system disturbances. The turbine is sized to
match the available steam, and the generator is selected to
produce active (megawatt) and reactive (megavar) power.
A properly selected generator and excitation system will
allow a ride-through during system disturbances and reduce Fig. 1. Generator capability curve.
the number of plant shutdowns. This paper provides some
guidelines in the selection and application of generator and load reactive power requirements and voltage support. There
exciter that are important for the overall system operation. is a tendency to purchase the generator with a lower power
These include the following: factor, i.e., larger megavoltampere rating than is necessary.
• generator rating and parameters; Larger generator frames contribute higher short-circuit currents
• excitation system; and introduce higher losses such as windage and core, as well
• neutral grounding considerations; as losses associated with higher current. It is better to
• protection considerations; purchase the generator with adequate megavar capability and
• synchronizing; a high-performance excitation system.
• integration into the power system; A typical generator reactive capability curve is shown in
• plant power system and utility interface; Fig. 1. Reference [2] states:
• system disturbances and islanding. the generator shall operate successfully at rated kVA,
frequency and power factor at any voltage not more than
II. GENERATOR RATING AND PARAMETERS 5% above or below rated voltage, but not necessarily in
accordance with the standard performance established
Generator rating (output) is given in megavoltamperes,
for operation at rated voltage.
which is the vector sum of its megawatt and megavar output.
The megawatt rating is determined by the turbine capability, Capability curves for other generator voltages can be obtained
and the megavar or power factor rating is selected to meet the from the manufacturer. At lower than rated voltage, the
underexcited var capability is reduced, whereas the overexcited
Paper PID 98–22, presented at the 1998 IEEE Pulp and Paper Industry
Conference, Portland, ME, June 16–20, and approved for publication in var capability is unaffected for 5% voltage variation from
the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Pulp and Paper the rated voltage.
Industry Committee of the IEEE Industry Applications Society. Manuscript Generator parameters that are of importance for the indus-
released for publication November 3, 1998.
The author is with Sandwell Inc., Montreal, PQ H3B 4V8, Canada. trial power system are short-circuit ratio (SCR), subtransient
Publisher Item Identifier S 0093-9994(99)03847-5. reactance ( ), and transient reactance ( ).
0093–9994/99$10.00 1999 IEEE
704 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 35, NO. 3, MAY/JUNE 1999
Fig. 2. Typical brushless excitation system. Rotating components are mounted on the same shaft.
SCR is the ratio of the field current at no-load rated voltage The response ratio is defined as the average rate of increase
to the field current required to produce rated armature current of field voltage during the first 0.5 s divided by the rated field
with short-circuited generator terminals. A higher value of voltage [5]. In general, the higher the response ratio of the
SCR is an indication of greater stability margin. With the exciter, the better is the transient stability of the system.
application of high-speed regulator and exciter, SCR in the A high initial response (HIR) excitation system is capable
order of 0.5 or higher is considered to be adequate. of attaining 95% of difference between ceiling voltage and
Subtransient reactance ( ) determines the initial generator field-rated voltage in 100 ms or less. However, for small- and
current during faults. A standard value in the order of 10% medium-size brushless units used in process plants, an HIR
for 3600 r/min (two-pole) and 15% for 1800 r/min (four- excitation system is costly and difficult to build.
pole) machines is used. Short-circuit contribution is always Two types of exciters, brushless and static, are available.
a problem for integrating a generator into an existing power
system. We do not recommend a value higher than 15%
A. Brushless Excitation System
for two- or four-pole machines. Transient reactance ( ) is
generally 150% of and a higher value compromises Medium- and high-speed machines with ratings up to sev-
on stability. eral hundred megavoltamperes utilize brushless excitation sys-
Another important criteria to be applied to the generator tems. A typical brushless excitation system is shown in Fig. 2.
and excitation system is that they must deliver a sustained The brushless excitation system includes an alternator–rectifier
short-circuit current of 3.0 pu for 10 s. This feature allows the main exciter and a permanent magnet generator pilot exciter
protective relay settings to operate within a reasonable time. (PMG), both directly driven from the synchronous generator
shaft. Field power for the main exciter is supplied from the
PMG, which has a set of rotating permanent magnets and a
III. EXCITATION SYSTEM
stationary three-phase armature. The high-frequency (420 Hz)
The excitation system consists of an exciter, voltage regula- output from the PMG is rectified to provide excitation for the
tor, and power supply. The system plays an important role in main exciter. The three-phase output of the rotating armature
recovery and voltage support during system disturbances. The of the main exciter is fed along the shaft to the rotating rectifier
salient features of the excitation system for a process plant system, the dc output of which is conducted to the synchronous
generator shall be as follows: generator field. Fuses are connected in series with the diodes to
1) high ceiling voltage in the order of 4.0 pu or higher protect the main exciter windings. Redundant diodes must be
from rated load field voltage; provided to prevent generator outage on the loss of a limited
2) field forcing or ceiling current of 2.25 pu or higher; number of diodes per phase.
3) capable of changing the generator field voltage from Brushless excitation system without PMG offers a faster
the voltage at the rated capacity and voltage to ceiling response to transients. In this system, an ac source, either from
voltage in less than 150 ms; the generator terminals or auxiliary power supply, is rectified
4) high response ratio. to provide excitation for the main exciter. A dc source from a
KHAN: GENERATOR AND EXCITATION SYSTEM FOR PROCESS PLANTS 705
D. Grounded Through a Grounding Transformer [Fig. 3(d)] operation or malfunction of the voltage regulator. The set
This method is used to provide low-resistance grounding for points or relay operating curve shall be below the generator
the same purpose as above and offers some advantages. A zig- and transformer limit curves. The generator limit curve is
zag grounding transformer with a neutral resistor is connected available from the manufacturer, and the transformer limit
to the bus. The ground current is not affected by the number curve provided in [12] can be used.
of units connected to the bus or system interconnections. 3) Reverse Power or Antimotoring [32 in Fig. 4(a)]:
In addition to the zig-zag transformer, each generator shall Motoring of generator occurs when, for some reason, the
be provided with a high-resistance grounding. This arrange- energy supply to the prime mover is cut off while the generator
ment will provide ground-fault protection during unit startup is still on the line. Primary indication of motoring is the flow
and synchronizing. of real power into the generator. The estimated power required
to motor the idling prime mover is as follows:
E. Low-Reactance Grounding [Fig. 3(e)] 1) diesel engine—about 25%;
This method is generally used where the generator is con- 2) hydro unit—0.2%–2%;
nected directly to a distribution system with solidly grounded 3) steam turbine—0.5%–3%.
neutral. The inductive reactance is selected to give Reverse power relays are supplied with time delay (up to
. Low-reactance grounding produces phase-to-ground fault 30 s) to prevent operation during power swings caused by
currents ranging from 25% to 100% of the three-phase fault system disturbances or synchronizing.
current. There is a possibility of iron core damage for internal The relay or element is set at about 50%–70% of the
faults. motoring power, which can be obtained from the manufacturer
and are zero-sequence and positive-sequence reac- or measured during commissioning. Two relays [32-1 and 32-2
tance, respectively. in Fig. 4(a)], each with an integrating timer, must be provided.
This method is not recommended for process plants.
The timer for 32-1 is set at about 3 s to protect against loss
F. Resonant Grounding of steam to the prime mover and can be used for sequential
tripping. The timer for 32-2 is set at 10–30 s to override the
This method is similar to high-resistance grounding using
power swings.
transformer-resistance combination, except that the resistor is
replaced by a reactor. The reactor is selected so that the induc- 4) Loss of Field/Excitation [40 in Fig. 4(a)]: Excitation
tive reactance matches the three-phase capacitive reactance of can be lost due to field open circuit, field short circuit,
the equipment. On line-to-ground fault, the system-charging regulation system failure, or loss of power supply to the
current is neutralized by an equal component of the inductive excitation system.
current. For a steam turbine, the unit will overspeed and operate as
an induction generator. It will supply power to the system and
V. PROTECTION CONSIDERATIONS receive vars from the system. The stator current can be 2.0 pu
This subject is well covered in [9] and [10]. A typical and a high level of current is induced in the rotor.
protection scheme for a low-resistance grounded generator Two zone impedance elements are used for detecting genera-
connected to a plant load bus is shown in Fig. 4. The following tor loss of field. The relay senses the variation of impedance as
criteria are recommended as a minimum for the selection of viewed from the generator terminal. Use relay manufacturer’s
protection relays: literature for setting calculations.
• proven experience of a minimum period of three years 5) Negative-Sequence Current [46 in Fig. 4(a)]: This fea-
and tested to ANSI/IEEE Standards; ture protects the generator against sustained unbalance or
• digital integrated protection scheme, microprocessor negative-sequence currents. The standards call for the machine
based, with self-checking and self-diagnostics. to withstand 5%–10% of negative-sequence current ( ) con-
Most of the digital integrated generator protection packages tinuously and higher values for shorter periods according to
do not have out-of-step and ground differential elements. formula . For salient-pole and indirectly cooled
These features shall be provided by separate protective ele- generators, the permissible 10%. Permissible is 40 for
ments. Some of the integrated protection units include four salient-pole machines and 30 for indirectly cooled cylindrical
trip relays which permit the grouping of protective elements rotor generators.
to provide trip output contacts. 6) Voltage-Restrained Overcurrent [51V in Fig. 4(a)]: This
A review and further consideration are given to the features is the final backup feature to trip the generator if faults are not
and setting of the following elements. cleared by other system protections. Block 51V in Fig. 4(a)
1) Accidental Energization (AE): This feature or an inter- for voltage transformer fuse-blown condition from device 60.
lock must be provided to prevent human error in the closing Device 51V is replaced by device 21 if coordination is needed
of the generator breaker when the turbine is not running. with high-voltage distance relays.
Integrated generator protection relays include a logic circuit Time settings are set long enough to permit other protections
to achieve this feature. to clear with a current pickup set at approximately 2 pu and
2) Volts per Hertz [24 in Fig. 4(a)]: This feature protects 100% voltage.
the generator and transformer if full voltage is applied while 7) Overvoltage [59 in Fig. 4(a)]: This device protects
the frequency is reduced, which might occur during isolated against overvoltage, such as might occur if there was a
KHAN: GENERATOR AND EXCITATION SYSTEM FOR PROCESS PLANTS 707
(a)
malfunction of the voltage regulator. The usual setting for This protection is highly recommended, even if the system
turbogenerators will be 110% of nominal volts and a time stability study shows that the loss of synchronism can be
delay of 15–20 s. detected by the device 40. System parameters change, and
8) Out of Step [78 in Fig. 4(a)]: When generator loses stability study is costly and time consuming.
synchronism, the resulting peak currents and off-frequency 9) Frequency—Over/Under [81 O/U in Fig. 4(a)]: In iso-
operations cause winding stresses, pulsating torques, and lated operations, overloading of generators will cause the
mechanical resonance. Loss of excitation relay 40 [Fig. 4(a)] system frequency to decay and the unit may be subjected to
may provide some degree of protection, but cannot be relied prolonged operation at reduced frequency. Underfrequency of
upon to detect the loss of synchronism. a turbine generator is more critical than overfrequency. Tur-
708 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 35, NO. 3, MAY/JUNE 1999
(b)
Fig. 4. (Continued.) (b) Auto/manual synchronizing scheme.
KHAN: GENERATOR AND EXCITATION SYSTEM FOR PROCESS PLANTS 709
used in utility systems, and has some merit, such as the appli-
Fig. 5. Integration with a duplex reactor. cations of HR grounding, and is less affected by the system
disturbances. The disadvantage in industrial systems is that the
power has to go through two transformations, thus incurring
A. Higher Reactance additional losses. However, for systems with large units or
Higher value of generator will reduce the short-circuit where the short-circuit contribution is large, this arrangement
contribution. However, a limit of 15% is recommended, as offers the best alternative. The step-up transformer winding
explained earlier. This approach is not practical for existing connection shall be Delta on the generator side and Wye with
installations with low margins in switchgear rating. neutral grounded on the HV side. A guide for the selection of
a generator step-up transformer is provided in [14].
B. Current-Limiting Reactor
E. Fault-Current Limiters
In applications where the short-circuit level exceeds the
switchgear rating by a small margin when the synchronous The fault-current limiter is applied to resolve the problem
generator is operating in parallel with the network, a current- associated with the increased fault levels. Their application is
limiting reactor with a bypass breaker can be used. The reactor on the rise in existing installations, and we have seen their use
will be bypassed when the generator is not tied to the network. even in generator circuits. There are two problems encountered
with this approach, which must be resolved before the decision
is made. The unit must have been tested and certified as a
C. Duplex Reactor
system to ensure that the downstream equipment is protected.
A duplex reactor is formed when two identical single-phase The other problem is related to protection coordination, which
reactors are physically arranged so that their magnetic fields is almost impractical to achieve.
are interlinked in an opposite sense. A fault-current limiter shall not be used in a generator
In a duplex reactor, the normal working currents in one circuit. The generator shall be tripped only for faults associated
winding partially erase the voltage drop in the other. With with the unit (turbine/generator).
balanced loading, the reactive kilovoltampere loss and reactive Faults within the generator zone are cleared fast by the
voltage drop are lower than for two independent reactors. generator protective relays. High set voltage restraint phase
With current flow in one winding section only, the duplex overcurrent relays provide backup protection for remote faults
reactor behaves the same as one of the two reactors. Further not cleared by upstream or feeder protective devices.
explanation is provided in [13].
The application of a duplex reactor is an excellent solution VIII. PLANT POWER SYSTEM AND UTILITY INTERFACE
to circumvent the problem associated with increased fault level
The majority of process plants receive power at voltage
resulting from the integration. However, system engineering
levels ranging from 34.5 to 230 kV. Reference [7] has pro-
must be carried out for the equipment selection. A single-
vided some guidelines for the protections and interface. Tra-
line diagram of an integrated system with a duplex reactor is
ditionally, two-winding transformers with Delta primary and
shown in Fig. 5.
grounded Wye secondary are used. There is a potential prob-
lem with the Delta (ungrounded) system when synchronous
D. Unit-Connected System (Fig. 6) generators or large synchronous motors are connected within
In this arrangement, the generator delivers the power to the the plant power system. On line-to-ground faults at the trans-
high-voltage bus through a step-up transformer, which is again mission line feeding the plant, the utility remote (sending
stepped down for utilization. This system is simple, widely end) breaker will trip. However, the high-voltage bus and
KHAN: GENERATOR AND EXCITATION SYSTEM FOR PROCESS PLANTS 711
[13] Industrial Power Systems Data Book, General Electric Co., Schenectady, Shoaib Khan (M’62–SM’72) was born in Jaunpur,
NY, 1968. India, in 1936. He received the B.Sc. degree in elec-
[14] Guide for Transformers Directly Connected to Generators, IEEE Std. trical engineering from Benaras Hindu University,
C57.116, 1989 (revised 1994). Benaras, India, in 1957.
[15] M. Shan Griffith, “Modern AC generator and control systems: Some He has more than 40 years experience in power
plain and painless facts,” IEEE Trans. Ind. Applicat., vol. 12, pp. systems engineering, application, and protective re-
481–491, Nov./Dec. 1976. laying for utilities and heavy industrial plants in
[16] C. L. Bencel, “Maintaining process continuity during voltage dips,” North America and overseas. Since 1975, he has
IEEE Trans. Ind. Applicat., vol. 18, pp. 324–328, July/Aug. 1982. been with Sandwell Inc., Montreal, PQ, Canada,
[17] T. L. Dillman, F. W. Keay, C. Rackowski, J. W. Skooglund, and W. H. where he is a Specialist in power systems and
South, “Brushless Excitation,” IEEE Spectrum, pp. 58–66, Mar. 1972. protection. He is also engaged in organizing, de-
[18] “Generator neutral grounding,” Genral Electric Co., Schenectady, NY, veloping, and teaching courses in power systems and protective relaying.
Pub. GET-1941A, July 1953. Mr. Khan is a member of the IEEE Industry Applications Society and a
[19] T. R. Beckwitt, “Automatic synchronizing considerations and methods,” Registered Engineer with the Order of Engineers of Quebec, Canada, and the
presented at the Western Relay Conf., Oct. 23, 1985. Association of Professional Engineers of Ontario, Canada. He is a recipient of
[20] J. C. Das, “Limitations of fault-current limiters for expansion of elec-
the IEEE Centennial Medal, and he has been active with the IEEE Education
trical distribution systems,” IEEE Trans. Ind. Applicat., vol. 33, pp.
Committee, Montreal Section, for over 25 years.
1073–1082, July/Aug. 1997.