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Power topic # 5590 | Technical information from Cummins Power Generation

Reliability Considerations in Simple Paralleling Applications

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By Rich Scroggins, Technical Specialist, Sales Application Engineering

Reliability in power generation systems, defined as the probability that power will be available at any point in time, is the primary reason standby generator sets are purchased. Using paralleled redundant generator sets is one method commonly used to enhance system reliability. Redundancy traditionally has been a requirement only in critical applications such as data centers and hospitals where an extended loss of power could result in loss of life or a substantial financial loss, as these were the only scenarios where the cost of a redundant generator and the associated paralleling switchgear could be justified. The availability of lower cost power transfer devices and paralleling control systems have in recent years made redundant paralleled generators an attractive option in less critical standby power applications.

Single Generators vs. Redundant Paralleled Generators

The decision on whether to use a single generator set or multiple paralleled generator sets will typically be based on reliability and cost. When a decision is made to use paralleled generator sets there are many considerations that need to be addressed to ensure a reliable system.

Reliability and Redundancy

The purpose of redundancy is to eliminate a single point of failure from a system. It is well documented that having redundant systems will make the overall system more reliable however this is always based on the assumptions that single points of failure are truly eliminated and not just moved to another part of the system and that the controls enabling redundancy dont introduce new failure modes which compromise reliability. Paralleled generator sets that rely on a single master control for signals to start and to close to a paralleled bus actually replace one failure point with two as the master control and the communication link between the master and the generator sets each represent single points of failure.

A standby generator set from a reputable manufacturer that has been maintained properly and tested periodically according to manufacturers recommendations is a very reliable solution. Adding a redundant generator with the inherent complexity of a paralleling system isnt necessarily going to make the system more reliable. Investing in a reliable generator set and a robust maintenance program so the generator doesnt fail is often a better investment than installing a more complex system to compensate for a failed generator set.

future as demand increases rather than installing a single larger generator that is oversized for the load. This will need to be balanced against the future investment required to add generators and switchgear and other required facility modifications.

Paralleling Systems
When a decision has been made to parallel generator sets there are several concerns that need to be addressed to ensure that the system is as reliable as possible.

Total System Cost

There are some instances where the cost of two small generator sets will be less than the cost of one larger generator set. The total installed cost of the system is often overlooked in basic standby applications. There are many factors which need to be evaluated beyond the cost of the generator sets. Foundation - A larger generator set may require additional structural support as the weight of the generator set will be concentrated on one spot, however smaller generator sets may require pouring multiple concrete slabs. Space requirements Multiple generator sets and their associated switchgear will take up more space than a single larger generator set although the smaller generator sets offer greater flexibility as individual generator sets can be maneuvered into smaller spaces than a larger set. Cabling Smaller generator sets enable the use of smaller cable and easier termination however paralleled generator sets will require additional cable runs which will be labor intensive, particularly if cable is run underground. Commissioning costs Startup and testing costs of paralleled generator sets are substantially higher than those costs for a single generator set. Maintenance costs Replacement parts for smaller generators will be less expensive than replacement parts for a larger generator however that difference is more than offset by the labor costs of maintaining two generators and switchgear rather than one single generator set. Capital Investment When the power demanded at a facility is expected to increase in the future initial capital investment can be minimized in some cases by installing a smaller generator with the intent of adding paralleled generators in the

Control System
A robust control system is critical to having a reliable paralleling system. A control system needs to minimize single points of failure and have fault tolerance measures built in. Key factors in a paralleling control include the following

Eliminate single points of failure where possible

The most effective way to eliminate single points of failure in a control is to use distributed logic and control rather than centralized control. Critical control functions such as generator starting, bus voltage sensing, synchronizing and closing to the bus should be executed by individual generator set controls rather than a master control. This way the system will have redundancy in critical control functions in addition to having redundant generators and the single point of failure is eliminated. Generator starting In a simple standby isolated bus paralleling application the start signal is sent directly from the transfer switches that sense the utility failure to the generator sets. Sending the signal through a master control adds no value and introduces an unnecessary failure mode. Paralleling bus voltage sensing For reliable paralleling each generator must sense the bus voltage independently rather than rely on a signal from a separate control Closing to a dead bus Generator controls should determine when to close their paralleling breaker to the bus. To provide the fastest and most reliable service to a dead bus generators must arbitrate between each other so that only one generator closes to the bus. Waiting for a permissive signal from a master slows the system down and adds an unnecessary failure mode

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Genset 1

Genset 2

Non-Emergency ATS Transfer Inhibit

Paralleling Breaker Aux Contact

Paralleling Breaker Aux Contact

Figure 1: Implementing a load add function

Synchronizing and closing to a live bus Generator sets synchronize reliably and quickly when there is no other control in the loop. External controls adjusting bias lines or otherwise interfering with the synchronizing algorithm introduce unnecessary complexity into the system.

Load Add/Load Shed

Load add and load shed schemes are used to make sure that there is always sufficient capacity to serve the most critical loads. Two levels of load add (one level for emergency loads and one level for all other loads) and one level for load shed (emergency loads are never shed) is sufficient for most simple, isolated bus paralleling applications. This can be implemented without the use of a master control. A master control may be required for additional levels of load add/shed. Although a master control can present a single point of failure the system can be designed so that failure of the master will not impact the most critical loads. A load add scheme is required in a paralleling system when a single generator is not large enough to carry all of the loads in the system. A simple load add scheme with two levels can be implemented using the inhibit function of the non-emergency load transfer switches and the aux contacts of the genset paralleling breakers (see figure 1). Emergency load transfer switches should not be inhibited and should close to the bus as soon as it is live. Non-emergency transfer switches can be inhibited until all of the generator sets come on line. A load shed scheme is required so that when generators are overloaded the non-critical loads can

be taken off line so that there will be sufficient capacity to serve the critical loads. Most paralleling generator set controls have a load shed or load dump output which can be connected to the load shed input of the transfer switches that serve the non-emergency loads (see figure 2). This will take the non-emergency loads off line in the event that the generator sets are overloaded. Note that to properly shed load transfer switches must be three position switches with centeroff positions.

Isochronous vs. droop load sharing

Most load sharing systems today are isochronous, meaning that the voltage and frequency are held constant however there are still controls being produced that use droop load sharing, which allow voltage and frequency to vary with load. Droop load sharing controls were once popular because they allowed generator sets to parallel with each other without communicating with each other. Due to the variation of frequency and voltage with a droop paralleling system the quality of power provided to the load typically is not very good and may not be suitable for some electrical equipment. Isochronous load sharing is the appropriate technology to use.

Random access paralleling vs. exciter paralleling 03 Power Topic #5590

Random access paralleling refers to a system in which the first generator at rated speed and voltage closes to the dead bus and then all the other generators actively synchronize and close to the bus. Random access

Genset 1

Genset 2

Non-Emergency ATS Load Shed

Load Dump Contact

Load Dump Contact

Figure 2: Implementing a load shed function

paralleling is the most reliable paralleling method and is most commonly used in critical applications. A less expensive paralleling method known as exciter paralleling is used in some paralleling applications. In an exciter paralleling system all of the generators start with their paralleling breakers closed and their excitation circuits de-energized. When the generators start they are connected to the bus but produce no voltage. When all generators reach starter disconnect speed their excitation circuits are energized and the generator bus voltage ramps up with the generators forcing each other into sync. Because exciter paralleling systems will not work until all generators either reach disconnect speed or are locked out they are not used in critical applications. Random access paralleling with active synchronization should always be used when paralleling gensets in critical applications.

Product Standards
Consulting engineers in the US consistently specify that paralleling switchgear must be rated to UL 891 or UL 1558. These standards ensure that industry safety guidelines are being followed and that the power transfer and protective devices and bussing have all been appropriately evaluated as a system for safety under fault conditions. Power transfer devices must also be rated appropriately for the paralleling application. UL 891 and UL 1558 specify circuit breakers listed to UL 489 (in the case of UL 891) or UL 1066 (in the case of UL 1558) for overcurrent protection and the breakers are typically used for power transfer as well as for protection. Draw out breakers are specified in critical applications such as hospitals and data centers, allowing operators to isolate faults and facilitate inspection and testing of breakers and easily replace breakers if necessary. Contactors that are not listed to a standard for paralleling equipment may not be suitable for a paralleling application as they may not have been evaluated for safety when subjected to the higher levels of fault currents present in a system with paralleled sources. Contactors that are components in UL 1008 listed transfer switches may not be suitable as a power transfer device in a paralleling application. UL 1008 recognizes and lists the entire switch mechanism, not the individual contactor. The individual contactor has not been type-tested according to the UL requirements and does not carry the UL listing separate from the transfer switch mechanism. In addition, UL 1008 lists switches that transfer loads between sources but does not test or recognize devices that parallel between two live sources. Because of these two factors it is not appropriate to apply the UL 1008 standard to contactors that are used to parallel between two live sources.

Fault tolerance manual mode

A key consideration in assessing the reliability of a system is the ability of the system to operate when certain components have failed. Having a pre-defined sequence of operations for a user to follow in a worst case scenario to manually provide power to loads is often a requirement in critical applications. A user should be able to manually start generators, initiate synchronization and close paralleling breakers. Manual operation does not mean that the generator control is not operating. It means only that functions are user initiated rather than system initiated. All system protection functions will still be active. The control will not allow a paralleling breaker to close if the generator and the paralleling bus are not in phase with each other.

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Installation Considerations
Installing and commissioning paralleled generator sets is not a simple process. A qualified manufacturer will have experience with protective relaying, system grounding, and other paralleling issues beyond the generator set functionality. Working with a manufacturer who has substantial paralleling experience over a wide range of applications and will assume responsibility for a correct installation is a key to a successful project even in the most basic paralleling application. There are several considerations that an experienced installer will address.

paralleling bus by separate breakers in separate compartments or sections in the switchgear line up.

Isolation of generators from the paralleling bus

To enable maximum reliability and safety there must be means to individually disconnect each generator from the paralleling bus located at the paralleling switchboard. Without this disconnecting means, typically an incoming breaker, a fault on one generator can make all generators inoperable and all generators will have to be locked out to do maintenance work on any generator in compliance with NFPA 70E Lock out tag out requirements (see figure 3). Without this disconnecting means much of the value of having a redundant generator will be lost.

Selective Coordination
The National Electrical Code requires selective coordination for emergency and legally required loads. Any downstream breakers must coordinate with upstream overcurrent protection such as paralleling breakers or a genset mounted breaker. Coordinating with a generator set mounted Molded Case Circuit Breaker (MCCB) with an instantaneous trip will be very difficult and will require in most cases that the downstream breakers are supplied from the same breaker manufacturer as the genset mounted MCCB. It is much easier to coordinate with a power breaker as is most often used in paralleling switchgear as they are typically equipped with programmable trip unit specifically for the purpose of coordination. When the generator control includes integral, UL listed overcurrent protection, coordination between the genset and the paralleling breaker is simplified because the overcurrent trip curve is optimized to allow the maximum permissible time delay while still protecting the alternator.

Ten second start requirement

The National Electrical Code requires that emergency loads are served within ten seconds of a utility failure. As ten seconds isnt enough time to start, synchronize and close multiple generator sets this requirement means that each of the generator sets in the system must be large enough to carry all of the emergency loads on its own. For example, a system of three paralleled 600 kW generator sets will not meet the NEC requirement if the emergency load exceeds 600 kW. To meet this requirement the sequence of operations should not require any interaction with a master controller. All control functions should be carried out independently by the generator and the transfer switch controls with no communication required other than a genset start command.

Supplier of distribution switchboard

Sourcing the generator and paralleling controls separately from the switchboard complicates a project. The contractor and consulting engineer must have a clear definition of what is included in the scope of supply for each part of the system. Dividing scope of supply wont be limited to equipment but will also include assignment of responsibility for meeting code requirements like selective coordination and separation of circuits, system testing and start up and ongoing maintenance and service. Having the same entity responsible for supply, commissioning and maintenance helps promote an efficient maintenance program.

Separation of Circuits
The National Electrical Code requires that Emergency, Legally Required and Optional loads are separated from each other. With paralleled generator sets that means that the Emergency, Legally Required and Optional loads must be fed from the generator

Distribution Panel G

G
Figure 3: Distribution panel with no incoming breaker

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Service and Support

One of the first questions that should be asked when choosing a supplier of a paralleling system is how will the system be supported in the future? Paralleling systems include engines, alternators, controls, switchgear and transfer switches and properly supporting all of this equipment requires a diverse skill set. Some suppliers only have experience with one component in a system and will need to involve other companies to troubleshoot problems that arise. Working with a supplier that has a proven track record of designing, installing and maintaining complete paralleling systems is the best way to ensure reliable operation over the life of the system. Questions to ask include Have the service technicians been trained and certified by the manufacturer on all components of the paralleling system? Claims that an engine dealer technician can service a paralleling system should be viewed with skepticism. Have the service technicians been certified with the make and model of engines being used in the application? Suppliers that use engines from different manufacturers may require different service organizations to support systems within the same geographical region. Does the service organization offer comprehensive maintenance programs for the entire system? Does the service organization have a demonstrated history of supporting paralleling systems in many different types of applications? What is the availability of replacement parts? Power transfer devices will often need to be replaced after faults. Replacing a proprietary contactor rather than a paralleling circuit breaker can result in a system being down for significant period of time. Replacing a proprietary component with a standard one may not be acceptable if the new device isnt listed for use with the existing overcurrent protection. If a control needs to be replaced is custom programming required for the replacement control and who is authorized to do the programming? What is the time frame for replacing the control?

Scalability
Paralleling systems are frequently expanded after they are put into service to accommodate increasing power demands. The ability to add a generator set and the associated switchgear in the future should always be considered. The system should have the flexibility to allow generator sets from a different manufacturer to be added in the future. Being locked in to a certain manufacturer limits flexibility for future expansions. Additional question to ask concerning expansion include Are the generators properly isolated so that new generators can be added without taking the facility off line? What is involved in modifying the control for expansion? If a different manufacturers generators are used for the expansion what will be required for the generators to parallel properly? Does the manufacturer have experience implementing field expansions, including expansions that include generators from other manufacturers. How can the system be modified to support utility paralleling if that is required in the future?

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About the author

Rich Scroggins is a Technical Specialist in the Application Engineering group at Cummins Power Generation. Rich has been with Cummins for 18 years in a variety of engineering and product management roles. Rich has led product development and application work with transfer switches, switchgear controls and networking and remote monitoring products and has developed and conducted seminars and sales and service training internationally on several products. Rich received his bachelors degree in electrical engineering from the University of Minnesota and an MBA from the University of St. Thomas.

Conclusions
The decision on whether to provide backup power with a single generator set or with redundant paralleled generator sets will be based on reliability and cost. The key question is does the redundancy coupled with the added complexity of a paralleling system increase the system reliability enough to justify the additional cost? When a decision has been made to parallel generator sets there are several considerations that need to be addressed to maximize the reliability of the system. The control system should be designed with critical functions distributed to the individual generator controls to minimize single points of failure The controls should have fault tolerance provisions such as load shed and manual operating modes. The installation must meet code requirements for coordination, separation of circuits and ten second service to emergency loads and must allow proper isolation of the generator sets. The system must be supported by an organization with a proven track record for servicing complete paralleling systems.

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2012 Cummins Power Generation Inc. All right reserved. Cummins Power Generation and Cummins are registered trademarks of Cummins Inc. The Power of One and Our energy working for you. are a trademarks of Cummins Power. GLPT-5590-EN (10/12)

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