Parallel

Basics
Paralleling Basics
& Paralleling
Controls
 Why Parallel Gensets?

Reliability
–In situations where load can be split up, failure of one
genset leaves the system still able to serve the most
critical loads.
• Better reliability for critical loads
• Poorer reliability for non-critical loads
• Reliability improvement depends on assumption of no
decrease in core genset control reliability
 Why Parallel Gensets?

Performance
–Small, high speed (1800 RPM) gensets can start
faster than larger slow speed machines
–High speed gensets have better transient
performance than slow speed machines
–Stiffer Emergency/Standby “Grid”
 Why Parallel Gensets?

Cost Effectiveness
–May be lower cost to install several small gensets
vs. single larger genset
• Especially for systems over 2000kW
• Installation Cost Reductions, Flexibility
–Servicing convenience
–Prime Power: reduced fuel consumption, better
load factor
–Interruptible Service Contract without Interruption
in Power Supply
Better not to Parallel When;
–Not economically viable
• gensets are very small (under 300kW)
– Smallest genset in system must be able to pick up 1st
priority loads
• existing gensets not compatible with new
–Not technically viable
• loads can’t be split and controlled (standby)
 Traditional Equipment Construction

G
 Paralleling Master
Control Control
1 per genset 1 per system

Distribution
Equipment
control

breaker Distribution
Equipment
 Paralleling Functions
REMOTE

Traditional Designs start with a non-paralleling

EC

ENGINE
genset….
– EC: Engine Control
• Protection for Engine GOV
• Start/Stop
• Operator Interface (Alarm/Metering) AVR GEN
– GOV: Governor
• Measure Speed/Control Fuel Rate
– AVR: Automatic Voltage Regulation
• Measure Voltage/Control Excitation CB

POWER
TO
LOAD
 Load Sharing

alternator
l o ad
=

kVAR =
A
kV

kW = engine

kW Demanded by Load

kVar Demanded by Load

Engines Produce kW--Fuel Rate Controls

Alternators Make kVAR--Excitation Controls
 Load Sharing
REMOTE

LOAD SHARE EC

ENGINE
DATA

GOV
ILS
AVR GEN

CB
• Add kW Load Sharing Controls: ILS
• Add kVar Load Sharing: Cross Current
POWER
TO
LOAD
 Synchronizing

REMOTE

LOAD SHARE EC

ENGINE
DATA

GOV
SYNC ILS
AVR GEN

CB

POWER
TO
LOAD
 Synchronizing
Improvements

60 Typical Synchronizing Range

59
FREQUENCY

58

57

56

1 2 3 4 5 6 7
TIME (SECONDS)
 Genset Protection
REMOTE

LOAD SHARE EC

ENGINE
DATA

GOV
PROT SYNC ILS
AVR GEN

CB

Minimum Paralleling Genset Protection: POWER

• Loss of Field (40) TO
• Reverse Power (32) LOAD
Alternator Capability Curve
 HMI
REMOTE
TRADITIONAL PARALLEL CONTROL
ALARM
LOAD SHARE EC

ENGINE
DATA

GOV
METER PROT SYNC ILS
AVR GEN

PARALLEL BREAKER

CB

Metering Uses: POWER

Set up Load Sharing: kW, PF, Amps TO
LOAD
Manual Parallel: V, Hz, Sync, Sw
 Traditional Design…
GOVERNOR GOVERNOR

GENSET ENGINE GENSET ENGINE

START COMMANDS
CONTROL CONTROL

AVR AVR

ALARM LAMPS ALARM LAMPS ALARM LAMPS

PROTECTION PROTECTION PLC PROTECTION

AC METERS AC METERS AC METERS

ILS ILS

SYNC SYNC

52-G 52-G

PARALLEL CONTROL #2 PARALLEL CONTROL #2 MASTER CONTROL

LOADS
 Load Govern Functions
REMOTE

• Import/Export Control ALARM

• Var/PF Control LOAD SHARE EC

ENGINE
DATA

GOV
I/E VAR/PF METER PROT SYNC ILS
AVR GEN

UTILITY CB CB
CLOSED SIGNAL

THESE FUNCTIONS ARE ALL REQUIRED POWER

TO
FOR UTILITY PARALLELING APPLICATIONS LOAD
 Impacts of Digital Control
LOAD SHARE REMOTE
DATA

ENGINE
Better Reliability
POWERCOMMAND
– Fewer Components CONTROL
– Logical Improvements
– Nearly Identical to Core Control GEN
Better Performance
– Direct Control
Lower Cost;
CB
– Duh…

POWER
TO
LOAD
 PowerCommand ANSI Functions GENSET

SURGE SUPPRESSORS
AM SW KW KWH PF 40 32 65 90 51V

VM SW HZ 27 81U 59

86
VM SW HZ 47 SYNC 25

SS
POWERCOMMAND CONTROL

SWITCHGEAR TRIP

CLOSE
 Digital Control
Alternatives
DIGITAL PARALLEL CONTROL
REMOTE
Governor by engine mfr.
(only) LOAD SHARE

ENGINE
Governor/Engine Control
DATA
EC
Integrated INTEGRATED GOV
Speed and Voltage Bias PARALLEL SPEED
BIAS
CONTROL
Paralleling Control by AVR GEN
others
Interface to Other Gensets VOLTAGE
BIAS
still Load Sharing ONLY.
CB
PARALLEL BREAKER

POWER
TO
LOAD
 Looking to the Future

Facility Life>>Electronics “Sales Life Cycle”

Need to Design for Replacement
 Paralleling Hardware:
Each Genset
Load Sharing
– Droop or Isochronous?
Synchronizing
– Auto and Manual
Genset Protection
– Reverse Var, Reverse Power, Sync Check
Monitoring and Manual Control
– Metering
• AM, VM, FM, kWM, Sync Scope/Lights
– Breaker Control
Load Govern (Optional)
 Paralleling Hardware:
Master Control
Interfaces gensets to facility
–Load Add
–Load Shed
–Load Demand
–Bus Protection
–Operator Monitoring Station
• Total System AC Metering
– Ammeter, Voltmeter, Frequency, KW
• Status Display
– Availability of Sources, Status of Load Service
• Manual Control Provisions
– Auto Load Control Bypass
– Manual Power Transfer
– Test
 Master Questions
Do I need a master control?
– Load Add Sequence
• What is it? What device does the add?
– Load Shed Sequence
• What is it? What device does the shed?
– Long Duration of Operation
• Do I need Load Demand?
What Features?
– Operator Interface
• Where? How Many?
• What information is needed?
• Manual Back-ups?
Instructions? Training?
 Power Transfer

 Means of Switching from Source to Source

 Switching Process
–Open Transition
–Fast Closed Transition
–Ramping Closed Transition
–Peak Shaving
–Base Load
 Functions
–Source Sensing, Timing/Logic, Utility Protection
–Metering, Manual Controls
 Isolated Bus, 3 gensets, 4 loads

Master Functions
G G G – Load Add/Shed
– Manual Load Control
– System Status
XXX XXX XXX
– AC Metering
– Load Demand
– Manual Parallel
– Bus Load Protection
XXX XXX XXX XXX Power Transfer
– Done by ATS, or not
needed
LOAD 1 LOAD 2 LOAD 3 LOAD 4
 Common Bus, 3 gensets
with utility main, 3 Loads
Master Functions
– Load Add/Shed
UTILITY/
G G G – Manual Load Control
MAINS
– System Status
– AC Metering
– Load Demand
XXX XXX XXX XXX
– Manual Parallel
– Bus Load Protection
Power Transfer
– Source Available
XXX XXX XXX – Logic

– Manual Transfer
– Source Metering
– Utility Protection\
– Master Sync
 Two gensets,
single breaker pair
G G
Master Functions
– Load Add/Shed
– Manual Load Control
XXX XXX – System Status
– AC Metering
UTILITY/
MAINS – Load Demand
– Manual Parallel
– Bus Load Protection
XXX XXX Power Transfer
– Source Available
– Logic
– Manual Transfer
XXX
– Source Metering
– Utility Protection
– Master Sync

LOAD
 Two breaker pairs,
two gensets, multiple load buses

G G

XXX XXX

UTILITY/ UTILITY/
MAINS 1 MAINS 2

XXX XXX XXX XXX

XXX XXX XXX XXX XXX XXX

LOAD LOAD LOAD LOAD LOAD LOAD

 Master
PCC3100
PCC
PCC3100
PCC TOUCHSCREEN ModLon
Architecture
PCC3200/1 PCC3200/1
3rd Party
Device

GENSET
GENSET GENSET
GENSET
Operator
Panel
PLC SYNCHRONIZER

MASTER COMMAND MODULE

(MCM3320)

M M
DIGITAL DIGITAL
PROTECTION
TRANSDUCER TRANSDUCER
52-G1
52-G1 52-G2
52-G2

PROTECTION PROTECTION

52-GM 52-UM
52-GM 52-UM

LOADS
IO 52-F1 52-F2 IO

LOADS LOADS
 INTERLOCK

1st START SENSOR

LOAD SHARE LINES

PCC PCC PCC

G G G
3 3 3
3 3 3
UTILITY UTILITY
XXX XXX XXX
FAILED FAILED

MCM MCM
3 3320 3 3 3 3 3 3320 3

3 3 3
3

XXX XXX XXX XXX

LOADS LOADS
 The Primary Reason for Paralleling
is to Achieve Added Reliability
KISS Avoiding Single Points
System Topology of Failure
Selection
– Pick by Application Need – Careful Review of
– Simple is generally better Design, Hardware, and
– System Design with Load Software
Add & Shed – Three Steps:
Reliable Components • Design it out
Manual Back-ups • True Redundancy
FMEA • Reliable components
– Role of Distributed Logic
Service & Support
 Master Control Systems
(Isolated Bus)

LOAD ADD/SHED START

COMMANDS COMMANDS

BUS BUS
PLC PROT METERS

START COMMAND, ALARM DATA

MASTER CONTROL

LOAD SHARE DATA

ALARM ALARM

EC EC
ENGINE

ENGINE
GOV GOV

METER PROT SYNC ILS METER PROT SYNC ILS

AVR GEN AVR GEN

PARALLEL CONTROL PARALLEL CONTROL

CB CB

POWER
TO
LOAD
 Hidden Failure Modes
Simultaneous Closure to a Dead Bus
– Single Bus VT Sensing?
Breaker Fail to Close on Black Start
Single Points of Failure

Breaker Fail to Open

– What to do depends on you are in the operating sequence…
Manual Volts/Hz Adjust
– Leads to load sharing imbalance
Speed Sensing
PLC & Components
System Power Supplies
Some HMI
– Hard to see multiple functions quickly (when switching screens)
– Failure?
Lack of Manual Backups to Auto Functions
– Using PLC to do both manual and auto controls (?!!!)
– What functions should have manual backup?
Operator Training (or lack thereof…)
– Posted Operating Instructions Help
 Protection Recommendations
Balance Protection vs. Reliability
– More Protection = Less Reliability
– Emergency Standby: Minimize Protection
Genset Protection
– Reverse Power
• Not more than 7% of Standby rating for 5 seconds
• Load Sharing Balance Time
– Loss of Field
• Depends on Alternator Capability
• Typical Cummins: 20% of Rated kVAR/10S
– Alternator Protection
• OverCurrent, Match to Alternator Need
• Single Phase Fault Protection
System Protection
– Under Frequency
– Over/Under Voltage
Utility Protection
– IEEE1547; or what utility will require
 Paralleling

 We’ll take care of the whole control system

 You need to put the pieces into systems
 Demonstrate Reliability, Performance, Cost