Syncronization and

Load Transfer of
Generators
presented by
Matthias Voloder

Woodward

This presentation is intended only for the individual or entity to which it is addressed and may contain information that is the Confidential and/or
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Index

• Synchronization
• Analog vs. digital controls
• Synchronization and load management
• Applications

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 Synchronizing
Isolated
Generator #1 Load Generator #2

Generator Grid

• Connecting different Voltage AC sources together without

stressing any electrical or mechanical equipment or
impacting the operation of the power plant, by matching the
voltage wave form of both sources.
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 Synchronizing

• Five conditions must be met for two systems to be

synchronized:
 The voltage amplitudes must be closely matched.
 The frequencies must be closely matched.
 The phase angle’s must be closely matched.
 The number of phases must be the same.
 The direction of rotation must be the same.

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 Why is Synchronization Important?

Isolated
Load
Generator A Generator B

Synchroscope
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 Synchronizing

• Why is it important:
When two or more electrical generating sets or systems
are paralleled to the same power distribution system,
the power sources must be synchronized properly.
Without proper synchronization of the oncoming unit or
system, power surges and mechanical or electrical
stress will result when the tie breaker is closed.
Extremely high currents can result from this, which put
stress on both systems.
These stresses can result in bent drive shafts, broken
couplings, or broken turbine quill shafts. Under some
conditions, power surges can be started which will build
on each other until both generating systems are
disabled.

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 Voltage Amplitudes

• Voltage amplitudes should be closely matched.

• The voltage amplitudes of the generators are determined
by the voltage regulators

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 Voltage Amplitudes Mismatch

• If two sources with unbalanced voltage are paralleled than

a immediate reactive current flow will be the result. The
direction of reactive current being from the system or
generator operating at the "higher" voltage to that at the
"lower" voltage
• For Gen-to-Gen application a kvar “swing” between the
genset can occur which will destabilize the reactive load
sharing operation and also the voltage level.
• For Gen-to-Grid a unintended reactive current flow will
occur, but the voltage level will be still maintained by the
grid.

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 Frequency Match

• The frequencies of both systems must be closely

matched.
• The frequencies of each system is determined by the
individual speed governors.

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 Frequency Mismatch

• A frequency difference prior to synchronizing will result in

an immediate active load balancing after paralleling (the
direction of active current being from the system or
generator operating at the "higher" frequency to that at the
"lower" frequency).
• For Gen-to-Gen application a kW load “swing” between
the genset can occur which will destabilize the active load
sharing operation and also the voltage level.
• For Gen-to-Grid a unintended active current flow will
occur, but the frequency level will be still maintained by
the grid.

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 Phase Angle Match

• Phase angle of each system must be closely matched.

• The phase angle of each system is determined by the
individual speed governors.

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 Phase Angel Mismatch

• Paralleling two systems when a phase angle between

them exists results in a circulating current between the
two systems, the value being dependent on the angle,
voltage and total impedance between them. As a result
the generator can experience severe mechanical stress
which may in some circumstances lead to severe
damage. Ideally the phase angle between the two
systems at the instant of paralleling should not exceed
about 7 degrees.

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 Number of Phases

• The number of phases in the system must be the same.

• The number of phases in the system is determined when
the equipment is specified, installed, and wired.

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Direction Of Rotation

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 Rotation Mismatch

• Rotation Mismatch is the worst case and contains all the

risks we have discussed under voltage, frequency and
phase mismatch.
• Rotation mismatch shall be easily detectable during the
setup & commissioning. Checking rotation field on the
generator taps, any terminals block in between and on the
grid connection taps shall minimize the risk down to 0%.
• In some application the rotation field can be is specified as
CCW. Which means the phase order is not A-B-C, but A-
C-B.

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 How is synchronization
accomplished ?
Normally, one generating system is used to
establish the common bus, and the oncoming
generator is then synchronized to that bus by
changing the speed of the prime mover driving
the oncoming generator and AVR output of the
oncoming generator.
Bus Frequency and Voltage (direct or via Phase Transfomers)

Control
Speed governor
Unit
Speed bias
Frequency & Phase Match Built-in
AVR
Feedback by Frequency
(direct or via Phase
Transfomers) BUS
Voltage bias
Voltage Match
Feedback by Generator Voltage (direct or via Phase Transfomers) Proprietary Information
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Methods of Synchronizing
• Manual - Operator Intervention
• Permissive - Sync Check Device 25M
• Automatic - Auto-Synchronize Devise 25A

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 Manual Synchronizing

Manually synchronized systems rely on monitoring

equipment to indicate to the operator when the two
systems are synchronized closely enough for safe
paralleling.
This equipment may include:
1 double voltmeter (can be included in a autom. synchronizer)
1 double frequency meter (can be included in a autom. synchronizer)
1 synchronoscope (can be included in a autom. synchronizers)
1 synch check relay (optional w/ autom. synchronizers)
1 speed control switch (can be included in a autom. synchronizers)
1 voltage control switch
1 push button for generator C.B. "ON at manual synchronization
(functions comes with an autom. synchronizers)

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 Automatic Synchronization

Automatic synchronizers monitor the voltage of either

one or two phases of an off-line generator and the
voltage of the same phases of the active bus. Small
units normally monitor a single phase. Large generating
systems normally monitor two phases.
Synchronizing depended on how closely the governor
controlled speed, and on how closely the synchronizer
had matched the generator frequency to that of the bus.

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 Function of Modern Automatic
synchronizer
• Compares the frequency and the phase of the two
voltages
 Sends a correction signal to governor controlling the prime mover of
the oncoming generator
• When Outputs of the two systems are matched
(Frequency and phase are both “in synch”), issues a
breaker-closing signal.
• May include voltage-matching circuits.
 Send correction signals to the voltage regulator of the oncoming
generator.
• Prevent closure command if the voltage of the oncoming
generator does not match the bus within set limits.

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 Phase Matching

• Frequency and Voltage-Phase of the variable source

follows the „target“ VAC source
• Fast, safe and reliable method to synchronize gensets
together or a genset to the grid
• Prefered for electronic and mechanical speed governores
whith a „linear“ or fast responsivnes to the synchronizers
speed and voltage bias. (For systems with a low quality of
control, the slip synchronization is the preferred solution ).
• Allows a manual closing of breakers and fuses where the
Voltage- and Phase-matching “Window” needs to be
maintained over a certain time periode. (e.g. fuse
operated coupling points, manual breaker operations).

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 Slip Frequency Synchronisation

• Frequency matching with an constant frequency offset

 normally between 0,05Hz and 0,2Hz
 the bigger the genset the smaller the offset
• The source with a variable speed control will be controlled
• Safe and reliable method to snychronize multiple genset
together and to the grid
• The synchronized power source will immediately output
power, so no risk for reverse powering
• Prefered for hydrolic and mechancial governors or engine
application whith variabel fuel quality like in Biogas, sewage
application where no stabil and consistant control quality can
be maintained
• Breaker command times needs to be considered
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 Analog Controls vs. Digital Controls
Part 1

Over decade of years the analog controls has been dominating the market.
Most or the majority of the simple synchronizers are stil analog type. They
have offered reliabe and robust technolgy while easy to set up and
maintain. For a lot of application they still offer the right features for simple
synchronizing and load transfer requirements. But over the last 15 years
digital controls has entered the tradional analog market by offering more
intergrated features which added value to customer requirements.
We will discuss the most important pro and cons of the analog vs. digtial
synchronizer controls on the next pages . We will use the easYgen-
controls as a reference model.

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 Analog Controls Pro’s & Con’s
Pro‘s
• Hight volume in the market
• Robust and reliable technology
• Easy to set up and operate
 Only a few parameters to tune
 No PC config tool needed
• Offering the functionality customer want and not more
Con’s
• For synch and enhanced load management, the number
of different controls in the application is increasing
(dedicated PN’s for Synch, Load share, soft loading
controls etc..)
• Only limited HMI (mainly LED’s) for operation status

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 Digital Controls Pro’s & Con’s
Pro‘s
• Hight flexibility in regards to the I/O
 (multi type analog bias outputs like +-20mA/+-10V dc)
• Robust and reliable technology
• Offering optional integrated features like protection, stable
timers, black start detection, load sharing, softloading,
communication over CAN, Modbus etc…
• Prepared to talk to J1939 ECU engines for speed biasing
• High number of communication available (Modbus, CAN,
Ethernet)
Con’s
• Digital controls got more parameter setting to do nearly
the same like the analog type
• Sometimes need a PC config tool (make it easier to
program) Proprietary Information
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 # of analog controls in a system = 12

#1 #2 #3
#4 #5 #6 #7 #8 #9

#10

#11
#12
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 # of digital controls in a system = 3

#1 #2 #3

The x-Ducer and process control function are also integrated in the genset
control package. The package are also available w/o display. It would be
also possible to replace the genset start-stop control. Proprietary Information
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 Synchronization with digital
controls
• Dynamic switch for PERMISSIVE, CHECK and RUN mode
• Stable timer garantue that not only the Phase, Frequency or
Voltage are controlled, in addidtion they also garantue that
only stable sources are synchronized
• Complete Protection (incl. Engine, Generator and Breaker)
• Phase matching AND Slip frequency mode in one package
• Redundant load sharing possible (automatic switching from
isochronous to droop LS in case the LS lines break)
• Remote Control via Com Ports possible (PLC conbection,
wiring savings)

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 Slip Frequency Synchronization in a
digital package

• Configurable frequency window o o

-90 +90
• Configurable voltage window
• Configurable synch. frequency differential 180
o

• Configurable breaker closing time

 Used to calculate when breaker close pulse is issued

 Formula for calculating phase angle at closing command

Phase angle = 360o * (Frequency differential) * (breaker closing time)

Example:
Phase angle = 360o * (0.3 Hz) * (0.2 sec) = 21.6°
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 Slip Frequency Synchronization
in a digital package

• Define close pulse duration

o

• Define stable timer o o

-90 +90
• Define maximum voltage differential
o

180

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 Phase Matching in a digital package

Select “Configure MCB or GCB”

• Define stable timer
• Define voltage differential window -90
o

+90
o

• Define positive and negative phase angle window

limits 180
o

• Define dwell time

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 Multiple Synchronization Modes in a
digital package

• RUN
 Active synchronization is performed. Bias signals to the -90
o

+90
o

governor and voltage regulator are active and breaker

close commands are issued.
• PERMISSIVE
o

180

 Passive synchronization performed. Bias signals to the

governor and voltage regulator are not active but breaker
close commands are issued.
• CHECK
 Active synchronization is simulated. Bias signals to the
governor and voltage regulator are active but breaker close
commands are not issued.
• OFF
 The synchronization can be disabled

The synchronization modes can be changed via a LogicsManager output

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 Breaker logic for ATS after the
synchronization
The following MCB/GCB transition modes are available:

1 Parallel 3 Closed transition

• Base load or import / export • Make before break
• Soft load / unload • Block loading / unloading

2 Interchange 4 Open transition

• Parallel for a limited time • Break before make
• Soft load transfer • Only dead busbar closing

MCB = Mains Circuit Breaker 5 External

GCB = Generator Circuit Breaker • External breaker control (PLC)
• Only “open” commands issued

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Sinle Unit Installation

GCB Only GCB + MCB

• Isolated • Isolated • Open Tr.
• Parallel • Parallel • Closed Tr.
• Interchange

SC= Speed Control

AVR = Automatic Voltage Regulator Proprietary Information
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Multiple Unit Installation

GCB + MCB
• Isolated
• Parallel
• Open Tr.
• Closed Tr.
• Interchange

• load sharing
• load sequencing
• AMF

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Multiple Unit Installation

GCB + MCB+ Group Breaker

• Isolated
• Parallel
• Open Tr.
• Closed Tr.
• Interchange
• load sharing
• load sequencing
• AMF

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 Breaker logic

1. Parallel
Baseload Import / Export

CT
2

CT
3

Load
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 Breaker logic

2.1 Interchange

220 kW
2

CT
3

220 kW
Load
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 Breaker logic

2.2 Interchange

Synchronize GCB
0 kW

220 kW

CT
3

220 kW
Load
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 Breaker logic

2.3 Interchange

Generator soft
110 kW loads

220-(1*110)
=110 kW

CT
3

220 kW
Load
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 Breaker logic

2.4 Interchange

Synchronize GCB
110 kW

220 – (1*110 kW)

0 kW = 0kW
2

CT
3

220 kW
Load
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 Breaker logic

2.5 Interchange

Generator soft
110 kW loads

220 – (2*110 kW)

110 kW = 0kW

CT
3

220 kW
Load
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 Breaker logic

2.6 Interchange

Open MCB command

110 kW
issued at zero power flow

0 kW
110 kW
2

CT
3

220 kW
Load
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 Breaker logic

2.7 Interchange

Plant load all on

110 kW generators

110 kW
2

CT
3

220 kW
Load
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 Breaker logic

3.1 Closed transition

Both breakers closed

for max 500 ms

220 kW

220 kW
Load
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 Breaker logic

3.2 Closed transition

Synchronize GCB, afterwards

0 kW
immediate Open Command to MSC

220 kW

220 kW
Load
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 Breaker logic

3.3 Closed transition

220 kW

220 kW
Load
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 Breaker logic

3.4 Closed transition

110 kW

110 kW

3 Synchronize GCB

220 kW
Load
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 Breaker logic

3.5 Closed transition

110 kW

110 kW
2

3 Generator soft loads

220 kW
Load
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 Breaker logic

4.1Open transition

220 kW

220 kW
Load
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 Breaker logic

4.2 Open transition

“Transfer time GCBMCB”
controls how long the load bus
is de-energized

The Bus is dead for the transfer time

220 kW
Load
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 Breaker logic

4.3 Open transition

Dead bus closure

220 kW

220 kW
Load
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 Breaker logic

4.4 Open transition

110 kW

0 kW

3
Synchronize GCB

220 kW
Load
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 Breaker logic

4.5 Open transition

110 kW
1

110 kW
2

3
Generator soft loads

220 kW
Load
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 Breaker logic

5. External
• Breaker control performed externally (PLC)
• Breaker open command depending on alarm class
• Generator unloaded performed prior to open command

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 Load sharing with digital controls
Load sharing over the CAN bus with the easYgen-3000
• Real load sharing with different sized engines
• Reactive load sharing with different sized engines
• Up to 32 genset units can load-share (limited number)
• Split bus applications are possible with up to four bus bars (different
segment numbers, w/o breaking the CAN links)
• Isochronous LS, the rated frequency will be maintained
• kW and kvar-Droop as a back up
• Dead bus Detection
• Load dependent start-stop possible (information exchange via CAN
link)
Analog Load Share Modules offers theoretically a unlimited number of
participants (nodes), but they are mostly limited to kW sharing.

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 Load sharing

Connection between the units via CAN 1

CAN 1
Mostly termination
resistors are to apply in
digital load share
networks.
Generator 1

CAN 1

More units
Generator 2
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 Load sharing

Active power load sharing

• Maintain frequency / maintain power utilization factor
• Weighting factor may be applied to load sharing
(> 50% more frequency, < 50% more power utilization)

Reactive power load sharing

• Maintain voltage / maintain reactive power utilization factor
• Weighting factor may be applied to reactive load sharing
(> 50% more voltage, < 50% more reactive power utilization)

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 Load sharing on Segements

Segment 1

Load
Load sharing

Segment 2
Load

Segment 3
Load
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Load sharing on Segments

Segment 1

Load
Segment #2 TRUE

Segment 2
Load

Segment 3
Load
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Load sharing on Segments

Segment 1

Load

Segment 2
Load
Segment #3 TRUE

Segment 3
Load
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 Load Sharing and Sequencing
Island parallel and mains parallel
System Reserve Power
Generator Load Capacity

Priority hierarchy
1. Assigned generator priority
2. Efficiency / engine size
3. Remaining maintenance hours
4. Assigned generator number

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 Alarm Classes for Protection

Class Action Result

Display Warning

Display and Horn Warning

Display and Horn Unlaod Gen. And open GCB Cool down Shut down

Display and Horn Open GCB immediate Cool down Shut down

Display and Horn Unlaod Gen. And open GCB Immediate Stop Shut down

Display and Horn Open GCB immediate Immediate Stop Shut down

For control purposes via LogicsManager to

change/modify sequencing or discrete outputs internal

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 Generator Protection
ANSI Code
• Over-/undervoltage [59/27]
• Voltage asymmetry [47]
• Over-/underfrequency [81O/U]
• Overload (IOP/MOP) [32]
• Reverse/reduced power [32R/F]
• Unbalanced load [46 measured]
• Definite time-overcurrent [50/51]
• Inverse time-overcurrent [IEC 255]
• Overspeed (MPU) [12]
• Measured ground current [50G]
• Calculated ground current
• Power factor (PF) lagging
• PF leading – loss of excitation [40Q]
• Phase rotation field CW/CCW
• Psetpoint  Pactual mismatch
• Unload mismatch (time out monitoring)
• Operating range failed

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 Engine Protection for Controls with
integrated start-stop feature

• Maintenance days exceeded

• Maintenance hours exceeded
• Over-/Underspeed (MPU)
• Unintended Stop
• Engine Stop malfunction
• Speed/frequency mismatch
• Start failure
• Charge alternator low voltage
• Red stop lamp (J1939)
• Amber warning lamp (J1939)
• Battery over-/undervoltage
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 Mains Monitoring and decoupling

# of Trip Levels ANSI Code

• Over-/undervoltage 2/2 [59/27 ]
• Over-/underfrequency 2/2 [81O/U]
• Import/Export power 2 [32]
• Power factor leading 2
• Power factor lagging 2
• Phase shift 1ph/3ph [78 ]
• Field rotation

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 Miscellaneous Monitoring

• GCB / MCB fail to close

• GCB / MCB fail to open
• Synch. Time Out GCB / MCB
Start / Stop
• Phase rotation mismatch generator / mains
• Mains decoupling
• CAN bus communications monitoring
• Parameter alignment (multiple units)
• Missing members (multiple units)
• EEPROM failure (internal CPU)
• Wire break analog inputs
• Discrete inputs
• FlexLimitsTM for analog values
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TM

Controlling the Power of Energy