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Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 8:07 AM

What would happen if a 1megawatt diesel generator set is accidently connected to the national grid and is not sychronized due to a UPS failure? will the damage be dependent to how far out of phase it is when connected. what is the cause of the damage, I understand it is likely to lift the Geerator off of its mountings but what is causing this?

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#1

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 8:27 AM

There should be circuit breakers and/or fuses which will be taken out before permanent damage can be done...

Otherwise its not a safe installation... John

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#2

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 9:37 AM

A 40 % over voltage spike will usually shut down the generator.

It may also cause anything on the grid to have a momentary over voltage spike which may cause a lot of cct breakers to trip, fuses to blow, unprotected electronics will fail, and electrical fires will start.

Your best friends house will burn down.

Whoever designed the UPS or hooked it up wrong would be sued.

Lawyers would get rich

Companies would go out of business

People would lose their jobs

Riots would ensue

Governments would crack down

Lawyers will get rich

Other countries would be upset about the rights of the protesters who just burnt down all the main street businesses

Lawyers will get rich

The Olympic torch would be extinguished

Europe would boycott the Olympics

War would break out

Someone would drop another nuclear bomb ...the end

Then someone would buy a slightly used generator and it would start all over again.

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#3
In reply to #2

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 9:49 AM

I like the first bit thanks but the rest, well! I agree the Lawyers will get rich.

But this did happen yet no fuses blew the genset rocked about a bit UPS did not switch over when it should and left the genset connected to grid for 30 seconds before it tripped.

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#4
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 10:04 AM

WOW! Your grid did some incredibly fast adjusting to the load change.

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#8
In reply to #3

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 4:23 AM

Simple, your Genny was luckily only a few degrees out of sync.....nothing more nothing less and by the sound of it it was slightly too slow, so it took no load and just dropped off automatically......

Remember, it is in sync actually every 120°, although we do not usually use 2 of the 3 sync points with conventional equipment, we search always for the same one, because that is how the sync equipment is usually wired up......but 3 points are there.

If you were in the middle between 2 sync points, I would be fairly certain that some quite nasty effects would be seen and equipment damaged before any breakers tripped.

To keep the lawyers away, this needs to be corrected by the manufacturers ASAP!!!

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#16
In reply to #8

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/13/2008 9:51 PM

I once saw a 4000hp synch motor closed onto mains at correct speed but out of phase with excitation already supplied. Dunno how the bloke managed to get past the interlocks, but he did. The event ripped both the Amortisseur Winding Shorting Rings completely off. Surprisingly none of the coupling bolts failed but the resulting shooting stars and fire were rather spectacular. In this case the only energy to return to the grid and create mayhem was that stored in the rotating mass (the MG set was coasting down from 1050 RPM to 1000). A system still at full noise with a big diesel could get quite ugly.

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#17
In reply to #16

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/14/2008 3:10 AM

You are SO right!

The forces developed can be really massive!!

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#12
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 1:28 PM

that was really funny

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#5

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 10:19 AM

I am not clear how a UPS failure would allow your gen set to connect to the grid out of synch..

Could you provide a diagrahm or more details??

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#6

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/11/2008 3:14 PM

When you close a generator out of phase it is pretty much a short circuit, and depending how far out of phase will dictate if you blow fuses, trip circuit breakers etc.. If you are lucky the larger of the two generation sources will take control of the smaller machine, thus locking it in phase.

What you are seeing when the generator jumps is the rotor being locked in phase with the grid. When a generator sees this kind of shock it can warp rotor, damage windings, damage frame & mountings, etc..

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#13
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 1:43 PM

this question may be off the mark a little but what are the parameters needed to force electricity back onto a grid whether using a generator or Solar/Wind Inverters. Does the voltage have to be higher than the grid ??? Thanks John

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#14
In reply to #13

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 4:59 PM

You actually have to excite the generator to increase voltage, but while connected to the grid, you cannot just increase the grid's voltage with a single generator as its simply too big, but what you actually do is that you take more load. Or supply more current, depending on how you want to look at it!!

Its that simple.

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#18
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/14/2008 12:24 PM

To Andy German

to be specific I am using this generator discussion to try to understand the EE principles necessary for the Solar Inverters or Wind Inverters to push the current back onto the grid. I have not been able to find a good explanation from the people that sell these Inverters. They use a PMM algorithm to optimize the Voltage Current from the solar panels but the is no explanation on this power is put back on the grid. Here is an except from a patent indicating it can be complicated

"Grid connected Ac inverters generally behave as a current source that injects a controlled AC wine wave current into the utility line. The controlled AC current is generated in sync with the observed utility zero crossings and may be exactly in phase, generating at unity power factor where upon real power only is exported. it is also possible to generate a variable amount out of phase-at other than unity power factor where upon real and reactive power is exported to the grid. An effective change in reactive power output can be made by either phase shifting the output current waveform with respect to voltage or by creating an asymmetric distortion to the output current wave form"

Am I making this too complicated??

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#20
In reply to #18

Re: Connecting an Unsynchronized Diesel Genset to the National Grid

04/14/2008 12:45 PM

Nope, it is complicated, but what do you want to know? CR4 will always try and help.

The electronics to put power back on the grid incorporate many safety locks, are complicated and expensive......Personally I feel that it is not worthwhile!!!

Supplying your own needs will save you a bundle.....but whether or not there is a payback in 5, 10 or even 20 years, is another question......I somehow doubt it!!!

You may also get agro from neighbors too with windmills and the like......

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#15
In reply to #13

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 6:04 PM

thanks Andy for the rating!

jemclau, the voltage should be the same, but the frequency should be "pushing" the grid frequency faster; earlier stated, that cannot happen, but trying would draw current, and the harder you push, the more current is fed into the grid, and the meter going faster backwards. Large, gridconnected windmills are started up with power from the grid, and the generator or auxillary motor gets the blades to rotate in the wind up to "grid speed" (the gearbox between blade and generator sets blades to rotate at say 20 RPM, generator 750 or 1500 RPM, 50 hz). Then the mill automatically connects in phase. When the wind blows faster than idle, that means to just overcome air-, gearbox- and bearing-resistance, the mill is not rotating faster (yes, a little due to iron-(eddy current) and copper-(resistance)losses), but trying to push the grid frequency faster. Thats why large windmills dont go faster than rated, despite the windspeed is increasing. They cant push the grid faster, because the grid is strongest. But more wind gives more "push" and therefor more current. It takes some sophisticated electronics to feed DC-current from solar and small windmills into the grid = expensive. And there is some loss in that conversion, but I dont know the precise efficiency-factor. My guess would be like a switched mode supply, say 94%? An AC-generator, like a motor, has an efficiency, I think, around 80-85 %?

regards, moe

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#19
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/14/2008 12:35 PM

Moe

My Danish friend I call Blue Tooth tells me that there is a lot of Wind Generation in the Land of the Vikings

I am specifically trying to understand how the Solar or Wind inverters can feed current back on the Grid. Here is an excerpt for a patent I am looking at that makes me think it is more complicated than the Inverters sales people know.

"Grid connected AS inverters generally behave as current source that injects a controlled AC sine wave current into the utility line. The controlled AC current is generated in sync with the observed utility zero crossings, and may be exactly in phase, generating at unity power factor where upon real power only is exported. It is also possible to generate a variable amount out of phase-at other than unity power factor where upon real and reactive power is exported to the grid. an effective change in reactive poser output can be made by either phase shifting the output current wave form with respect to voltage or by creating an asymmetric distortion to the output current waveform."

I quess with this info I am asking if there are controls on the Inverter that regulates the power going back to the grid?


Thanks John

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#21
In reply to #19

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/14/2008 4:27 PM

Hi jemclau, I dont know if you're familiar with the term "power factor", but its (the short version) a term used to describe the angle of which the current is out of phase with voltage. At resistive loads, power factor is 1, V and A is in phase. However, when the load is reactive, and that can be both capacitive or inductive, the power factor goes lover than 1. If we connect a transformer to 50 hz AC, it has an inductive load+a resistive load, powerfactor 0,9. If we then put a capacitor across the transformer, the power factor becomes 1 again, that is if dimensions are right. The power companies likes resistive loads, because reactive loads increases current in the generator, making it hotter and you dont pay for the higher current x same voltage=more watt. They can specify loads to be better than, say "power factor 0,95".

The term "unity power factor" must be, when power factor is 1.

And the term "excitation" must be when genset is trying to go faster than grid, please help, Andy??

I dont think, there are controls on the inverter to regulate how much power is fed into the grid. That depends on DC voltage at the generating unit or battery. But there could be some sort of adjustment relative to max DC current, minimum DC voltage threshold and so on. And a grid-tie inverter automatically adjusts power out from input DC voltage.

The info you mention is for very specific grid loads specified by grid company.

regards moe

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#25
In reply to #21

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/15/2008 11:41 AM

Generally an AC Generator has a small DC Generator to provide a DC voltage for the AC Rotor.......if you follow that!!!

By adjusting the amount of DC current flowing through the rotor, you increase or decrease the output voltage (excitation) or the AC Generator......

Though when an AC Generator is connected to the grid, increasing excitation does not increase voltage, the grid is too large for that, but it causes that Generator to supply more current into the grid.....that is how load is taken or shed.....

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#27
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/15/2008 1:26 PM

Moe thanks for the info Yes I know power factor well since here in the States the electric company charges you extra for a poor power factor and why they use capacitance in form of lighting and capacitors for boosting the power factor . However I did not know that the reactive load increased current in the generator. I will have look into this further. Back to my main question the solar and wind companies that sell inverters do not have any explanation of any technology needed to feed current back to the grid so it must be a transparent process that they easily take care of. One of the companies SMA has sent me a CD so I will see if they explain in the CD. Thanks again

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#28
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Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/15/2008 10:17 PM

I can't tell you the exact method any manufacturer uses, but here is the basics. A synchronising transformer is connected to the mains. The isolated extra low voltage signal is used to control the phasing of the inverter. It is not especially complicated and a similar method of phase control is used in larger DC packages to synchronise the switching of the power semis typically thyristors in that application. For the control of an inverter that is connected to mains, synchronisation is probably the simplest task. Zero crossing is easy to detect and a sample and hold indicates which side of zero the voltage has come from (and by default where it must go next) which takes care of the 180deg out of phase condition. Other considerations are current control, available exportable power, and supply failure, some sort of PID with multiple summing / error detectors is expected for this. Mains failure lockout in this application is as important as synchronisation because the low impedance of a de-energised grid is effectively a dead short.

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#7

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 12:44 AM

#$%&*!]}\|@##&^*

And then some

It happened on a isolated Military Base with Auto on/switch over in commercial power failure..shook the bejesus out of the power house..four big Cummings diesels w/4000 kw each..all on.....civilians claimed we backed up water at Grand Coolie Dam.

Power house was set in blasted out granite rock with mucho concrete poured foundation.

Being a Californian it felt like a substantial earthquake ...poped a couple of hold down bolts but these were between a sub frame on each unit-to-foundation connection.

Knocked the shift operator off his feet (the guilty party) and tipped over the air compressor....air start on the diesels.

Units un damaged...I calculated they stopped in three revolutions..from 600 RPM..

MR. GUY

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#9

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 8:01 AM

Hi speed droop, the generator will see the grid, which we will say is out of phase with genset, as a shortcircuit, and if the fuses dont blow, and they dont due to the time it takes to melt the small wire inside the fuse, the generator will try to get in sync with the grid, and in the milliseconds that takes, there are very large forces released between the generator and the dieselengine. All the moving parts in the total genset has to stop and start turning again in sync in milliseconds, and if you calculate how much weight is in motion, there you have you answer. The kinetic energy forces are large and may blow up or severely damage the genset. On smaller gensets 200kw and 400 kw we have seen bended crankshafts, burned out main switches and blown main fuses because operators were not paying attention. We have now semiautomatic main switches on all gensets, which will connect only when genset is in phase with grid. To connect to grid, we have to start genset, reach genset operating temp, monitor both grid and genset phase simultanous(spelling?), adjust genset speed to very close(faster) to grid speed, and when wait, while pushing a button, till genset is in phase, and the main switch(relay) automatically connects spot on. Remember, you cannot force the grid with a 1Mw genset as the grid is much, much stronger.

moe, electrician.

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#11
In reply to #9

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 1:24 PM

Good answer, gave you a GA point.

Everything you wrote is correct.

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#23
In reply to #9

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/14/2008 9:51 PM

That is it exactly, Synch motors are synchronised the same way, a common device was the Bell Synchronising Relay (I'll just hide while things get thrown at the very mention of its name), fortunately these days electronic relays are quite accurate and have superceded that old clunker.

For manual synchronisation of alternators I used to use the lamps dark method, but there were all sorts of electromechanical devices such as the afore mentioned Bell beast and the Siemens Halse. The Siemens Halse was a common synchroniser at power station level and was correspondingly expensive. For small applications the lamps methods were vastly cheaper than even a synchroscope. I found the lamps dark easier and possible safer than lamps bright. Most of what I've dealt with was closed at the crossing point rather than try and run two systems synchronised but disconnected for any length of time. Circulating currents still occur to some degree as load sharing settles down but there is nothing catastrophic.

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#26
In reply to #23

Re: Connecting an Unsynchronised Diesel Gen set to the National Grid

04/15/2008 11:45 AM

In the RN in my time, we used one lamp dark, two lamps bright, rotating clockwise.....

There was a syncroscope meter as well, but I do not know anyone who actually used it for synchronizing before paralleling....always the lamps.

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#10

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/12/2008 12:50 PM

There will be darkness...

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#22

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/14/2008 8:41 PM

Having built the auto parallelling circuit for the L1011 aircraft back in the 60's, I fully understand what you are talking about. My first attempt, I had the circuit set to parallel at 180 degrees. These were 120 KVA generators running at 12K RPM with a drive shaft that was necked down to 3/8 inch.

I threw the switch and the ground plane shook violently. We had the three phases bundled on standoffs about 3 inches from the ground plane. THe generators were running on Constant Speed Drives from big old 300 HP drive stands. I can state unequivocly that it didn't parallel. The over current relays dropped it off line about 1 cycle later but for that 1 cycle, we had rather unrestrained currents flowing with the attendant magnetic forces.

I'm not surprised that you broke a few bolts and the building shook. Good object lesson.

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#24

Re: Connecting an Unsychronised Diesel Genset to the National Grid

04/15/2008 4:26 AM

Great Forum in typical CR4 style, gentlemen. I'm interested in your opinions for < 2MW syncronisers and what you think are the best breakers for protecting the sets. I'm using Woodward GC32s here as the Monkeys can't break the password and frig with the thing [they frig with everything here]. I'm using Megatika EMCBs locked inside a cabinets only I have keys to. Every couple of weeks I have a problem which I think is from the 'network'. I use that term very loosely. It consists of gensets and switch stations all over the place 'networked' together. I think it occasionally switches an out of sync unit online or into my affected set. So my set(s) sees broken sine wave and overloads in the time it takes for the EMCB to kick out. I can change the sensitivity of my EMCBs but don't want the type of quasi catastrophic events many have described here. Anyone got some suggestions? Cheers

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