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www.iaemp.info Digest No-27 14 17
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TECHNOVATIONS

November,2012

Compilation of discussions in iaemp yahoo group

(Contributed by : Shri Arvind Rastogi, CEA,Life Member, IAEMP, Raipur e-mail: arvind_rastogi@hotmail.com )

TOPIC: DG SETS
Shri Arvind Rastogi

DG SET FUEL CONSUMPTION AT VARYING LOADS DG set manufacturers data normally specifies the SFC (Specific Fuel consumption) in gm/kWh. For example, normal fuel consumption at 100% load, and 75% load, for : 1) 380KVA DG set : 76 lph, & 58.2 lph, respectively; 2) 250KVA DG set : 53.3lph & 40.8 lph, respectively; A thumb rule of 4 units /L is considered as the best performance at full load. Suggested methods include (1) Test with weighing machine; (2) Measuring fuel consumption with dip measurement and measuring the load with a load manager. 1.0 Test method : 1.1 Use fuel by weight, not volume, as volume will change drastically with temperature. The supplier will state fuel consumption in gms / kWh. 1.2 Use a purely resistive load bank, and a calibrated ammeter. 1.3 Get a 20-30L bucket and place it on a precise weighing device. Calibrate the weighing device and have the fuel circulated back to the same bucket. (A small bucket, vis-a-vis a 500L tank, with a sensitive weighing device will need only 5 minutes at each load, to see the weight difference.) 1.4 Warm up the unit on the 500 L tank and disconnect both suction and return hoses and drop them into the test bucket and weigh the fuel, bucket and hoses all together; Then start 1/2 load test for 5 minutes. 1.6 Stop and refuel the bucket with ambient temp fuel (the fuel will be quite hot from the 1/2 load test, if the set runs more than 5 minutes). 1.7 Then test again at full load for 5 minutes For a 380 kVA DG set, the typical values could be around 100% load 3.6 kWh/L; 75% load 3.3 - 3.2 kWh/L; 50% load 2.6 - 2.8 kWh/L; 25% load 2.3 - 2.5 kWh/L; If PF correction is provided in the circuit, the KWh/L improves further.

*This issue is sponsored by M/s TECHNOVATIONS,Bhilai Web site: http://technovations.in/ e-mail: energy@technovations.in 1

LOAD FACTOR Load Factor is the average power divided by the peak power over a period of time, and is purely dependent on the loading pattern, not on the DG set. Similarly, PF is also a load related parameter. There is a misconception that PF for a DG set should always be 0.8, which is not correct. DG set can feed and run on Unity PF, as long as its rated power delivering capacity is not exceeded (which is determined by the engine HP). UNDERSTANDING RATINGS OF A DG SET If a DG set is rated 160KVA, it implies that : The DG will generate 160KVA, in continuous duty; At rated load PF of 0.8, it could take a load of 160KVA * 0.8 = 128KW, on a continuous duty cycle. For motors, a load factor of 110% for 1 hour should be considered further; Starting current : 60% of FLC, for highest rated motor; One comparison: If load PF is 0.9, than max KVA load = 128/0.9 = 143KVA (Instead 160) If load PF is 0.6 than max KW load permitted =160*0.6 = 96 (Instead 128) This will clarify all doubts related to sizing of an equipment which generally depends on insulation of equipment and temperature rise. DG SET SYNCHRONISATION PROBLEM : 3 Nos of 1250KVA DGsets were synchronised. The distance bet-ween the DG Sync Ouput Panel and the Main MV Panel (PCC) is 140M, connected through bus duct. While synchronising, following voltage readings between Phase & Neutral were observed : R-N : 190V; Y-N : 220V; B-N : 222V; What could be the cause for such difference, and how to eliminate this? ANSWER : The following needs to be checked : 1. Output voltages at the DG ends. 2. Output voltages at PCC end. 3. If DG output voltages are equal at DG end, but dropping at PCC end, it may be due to loose lugs, joints or cracks in bus duct of that particular phase. These joints need to be checked. Loose joints are not uncommon in long bus bars. Using interleaved bus duct may solve the problem. A resistance check of all joints on each phase of bus duct should be conducted. There may be some high resistance areas where the voltage is dropping. Loose joints may result in partial single phasing. 4. Voltage at grid bus to which the DG Sets are synchronised. 5. Neutral circuit path this may have some loose connection, or rusted bolts. All the alternators neutrals must be grounded, neutral earth checked to ensure proper value upto DG set neutral bus?

Are these connected through a neutral grounding switch? In synchronized running, are all the neutrals grounding switch & nbsp in ON position, or only one is ON? In parallel operation, only one alternator neutral should be grounded, and other should be in open position. 6. Method of synchronization, ie., Lamp, or Synchro-scope, or both ? 7. Load Type : This could be also due to a large number of PWM-VFD connected to the particular bus. It could be due to the different charging time periods of capacitors provided in the VFD rectifier units, & different conduction periods, due to difference in inductance value of the supply feeder bus- ducts. The change in inductance value is more when more number of step-down transformers, voltage stabilizers, VFD reactors, etc., are involved in the network. More number of single phase drives will also enhance the severity. Generally, loads are never always balanced. Balancing 100% 1P & 3P loads, is a difficult task. Normally, any initial planning considers loads to be evenly distributed, phase-wise. But subsequent expansions, addition of new equipments / facilities, creates unbalances in load. Also, timing of load to come into operation can disturb the balance. Heating loads vary subject to temperature requirements. An extensive audit or study of the entire load distribution, can only lead to the problem. Though, in this case, 99% loads are inductive motors. Single phase loads are only lighting & UPS, which are also uniformly distributed. With Grid power for the same loads, the current in all 3 phases are 2750, 2810, 2775A. 8. Insulators also need to be examined. These should be of specific grade, creepage, etc. Even a simple hair-line crack, internally or externally in insulators, due to over tightening of insulator, could be the culprit. It is likely that current is leaking through an insulator and getting earthed. Further detailed analysis was conducted on above problem wherein there is drastic voltage reduction in R phase alone. Synchronisation was done with a synchroscope. The synchronised output is connected to MV panel through the bus-duct of 150M length. Bus duct connections were thoroughly checked and tightened wherever loose connections noticed. Still, the voltage variation in R phase remained. The voltage reading observed at different load levels is furnished below:

Sync. output voltage at DG Voltage at MV Panel room ACB [V] RY YB BR RN YN BN RY YB BR RN 420 429 426 250 246 255 374 369 385 160 424 428 426 252 251 255 389 396 380 218 428 420 421 251 249 252 388 410 392 202 428 432 433 253 247 249 390 405 396 222 431 432 430 252 251 251 401 429 415 227

YN 230 252 230 249 250

Load Current of the system [A] BN R Y B 246 2574 3277 2482 239 2000 2520 1915 227 1336 1575 1238 256 1107 1228 1007 257 576 544 430

Based on above data, following conclusions emerge : 1. Earth connection of DG set and all PTs need to be checked. Neutral earthing could be a problem. 2. Load currents are indicative of unbalanced loads. Single phase loads connected to R-phase may be inductive (reactive type, eg., UPS), thus dropping the voltage. Loads on all 3 phases, first have to be balanced before further conclusion.
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3. Even at 550A, voltage drop in RN is very high, which is indicative of the severity of the problem. 4. Since DG end voltages are normal and drop is in the voltage at MV panel end, it is evident that problem is confined to the bus and the joints. If possible, inter-changing the bus-bars could help to narrow down the problem area. 5. Since voltage drop is observed in one phase only, changing the cable connection of R-Phase to other phases in such a way that phase sequence remains the same, will localize the problem area, if the drop in voltage gets shifted to the other phase. 6. Calculations further reveal that : Voltage drop = I (amps ) x Resistance of bus bar. (250 - 160) = 90V = 2572 x 0.035 (252 - 218) = 34V = 2000 x 0.017 (251 - 202) = 49V = 1336 x 0.0367 (253 - 222) = 31V = 1107 x 0.028 (252 - 227) = 25V = 576 x 0.043 R-Phase bus bar resistance is almost twice the Y and B-phase bus bar. Resistance of the bus bar need to be checked with micro-ohm meter during shut down time. Corrective action may be required to reduce voltage drop by adding more conductors. Thorough checking of bus duct joints, connections, did not reveal any shortcoming. The contact resistance in the joints was found to be well within the limit of 0.4m . Finally, it was concluded to lay a separate external cable of 300mm2 from DG ACB to MV panel ACB, only for Neutral, and disconnect the joints of Neutral in the bus-duct on both ends. This has resulted in the voltage in all 3 phases to improve to 224, 230, 227V, well within the limits. But now the current in the system is getting unbalanced, even for the balanced loads. The current readings are 2600, 3200 and 2650A in the 3 phases. The current in the Y phases is now higher than other 2 phases, though the loads are balanced. Following tests shall have to be persisted with to find out the reason for unbalance : (a) Continue to improve PF on DG to approach the designed value of Alternator; (b) Increasing receiving end voltage to reduce current in circuit, and check for any unbalance in voltage; (c) If it is still unbalanced, switch off all 1phase loads keeping emergencies in circuit, and again check voltage; (d) Check DG output at No-load? Neutral current flow is about 15A; Current should be checked in the neutral with R, Y, B phases.

PROBLEM : An installation of 2x17.5MW / 6.6 TGs, is encountering a problem with active and reactive load sharing while paralleling each other without grid. Both sets have 505E Woodward make Governor. The matter was referred to Woodward who advised to install auto load sharing equipment. Some experts suggests it will not be required, the governor droop adjustment will be sufficient. ANSWERS : The governor droop arrangement is OK. It has been tested and tried in other installations. This problem occurs if the Droop Characteristics of both Governors are not same or the response time of both is different. A PLC could be a solution as it will optimize the matching of the characteristics. The OEMs have the instruments for response measurement. Active load sharing depends on Governor & Reactive load sharing on AVR. These have to be adjusted / fine tuned as per response of individual machines to resolve the problem

PROBLEM : A hydro power generating machine rated as 5000KVA/0.8pf, is supplying electricity to grid. 1) Can this generator produce more than 4000KW (=5000*0.8) per hour? The overload capacity may be ignored. The power producer has shown that machine has generated more than 4000KW/hour, to the extent of 4500-4800KW/hour. 2) Can it be claimed that if there is a PF increase on load side, it can generate more power? This possibility can occur since it is supplying power to grid, with PF of 0.94 in a good season when no agricultural pumping load exists. 3) Can a generator increase PF on own side and increase generation kw per hour? ANSWERS : Active power output (ie., kW / MW capacity) of a hydro-generator is limited by the rating of a hydro-turbine. The PF of a generator can be increased to unity or can be operated in leading PF by adjusting the field excitation. However, for stable operation, hydro-generator should be operated within the parameters specified by the manufacturer, generally in Power Chart / Capability diagram. As long as VAR demand is less, and the generator operates within its stability limits, it can always generate the same MVA, but at a less lagging PF. In effect that would translate to generating more active power or MW at a PF > 0.8. Generator cannot produce more than 4000KW. KW is independent of PF. In the electrical system, if PF decreases, the KVA increases to keep the KW constant. On the other hand, it is possible to increase the PF at Generation side even if the PF of Grid is low and hence generate more than 4000KW. In one case, 64-66MW is being generated from 75MVA Generator designed to generate 60MW at PF of 0.8. (Explanation : 75MVA Generator is designed to generate 60MW at 45MVAr, ie., 0.8 PF. But if 66MW is generated, and supplies 25MVar only, then the Generator is loaded upto 70.6MVA. Similarly, if it generates 66MW and supplies 30MVAr only, then the Generator is loaded only upto 72.5MVA, instead of 75 MVA rated capacity. Thus we can generate more Active power (KW or MW) without overloading the generator. Only the MVA or KVA capacity, which can be known by Generator stator current limit given by the manufacturer, should not be exceeded.) Generator Stability practically does not allow improvement of PF beyond a limit. Often, the Generators are operated only slightly above the rated PF, for fear of approaching the zone of instability. However, each case is to be analyzed separately, whether operating in Islanding mode or Synchronous mode, etc. But if the grid voltage has to be supported in case of low Grid voltage, than generation will have to be reduced for supplying additional reactive load (KVAr) so as not to overload the Generator. Referring to the agricultural load discussed above, first of all, when the pump runs on full load (invariably it will) the PF will naturally be very good (>0.95). Secondly, the length of the rabbit conductor adds resistive load and builds up the PF nearer to unity. Hence, low PF can never be imputed to the agricultural sector. There are very rare cases when the IP set runs on no-load or low-load. In that eventuality the motor burns out very soon. The reason for reduced PF can never be IP sets. GENERATOR FIELD FLASHING PROBLEM : Why is field flashing required for the Alternator? Is it a temporary requirement, or is this field flashing continuous during running (when AVR is in line)?

ANSWERS : Generator field flashing is required when generator voltage does not build up & the generating system does not have field flash capability by itself (including the voltage regulator). This condition is usually caused by insufficient residual magnetism in the exciter & generator fields. Sometimes the residual magnetism in the alternator is lost. This happens if the field supply is reversed. At that time, the alternator will not produce any voltage. In excitations with shunt-connected supply, there is not enough remnant voltage in the rotating generator to build up the generator voltage autonomously via the converter. Residual magnetism can be restored by flashing the field with external power source, thereby causing a current surge in the generator field circuit. To accomplish this, special field flashing equipment is needed. When the field flashing equipment is being supplied with power from a DC power source (power station battery), a resistor is used to limit the field flashing current. Excitation of the generator is started by closing the field circuit-breaker and the field flashing breaker. This supplies current to the field, which excites the generator up to 10-30% U. The generator then supplies voltage to the converter via the excitation transformer. Starting from approx. 10% of the generator voltage the firing electronics and the converter are able to continue the voltage build-up, so that the field flashing circuit is relieved of current. Once the voltage exceeds approx. 70% of U, the field flashing breaker is finally opened, having no current. The diode bridge at the input to the field flashing breaker prevents a backflow of current to the field flashing source. In the absence of regular arrangement, a small 9V battery also has solved such problems. There is no need of field flashing during normal running of generator. NEUTRAL GROUNDING RESISTORS [NGR] Q : What is the necessity of providing NGR for the DG set which are generating MV Supply of 13.8KV. ANSWER : NGR is use for limiting the fault current. It is used at neutral point, when the generator winding is star, to limit the current. PROBLEM : An industry has 2 x 500KVA DG sets, of which one (Cummins engine) is equipped with electronic governor, and other (Caterpillar - D 3152 model) with a mechanical governor. Both the sets are operated at the same load of 300 KW, and it is observed that the set with electronic governor consumes 65 L/Hr, and generates 4.5 Units/L, whereas the corresponding value for the mechanical governor type are 85 L/Hr, and 3 Units/L. SOLUTION : Though electronic governors perform better than mechanical ones in handling the fuel input with variation in load, the difference reported appears very high. The comparison should be for identical engine cylinder volumes (cc); and for engines of same age. Normally, unit generation of any generator is from 3.5 to 3.85 Units/L. Fuel efficiency is a direct phenomenon of : Age of engine; Type of load fluctuating, constant, etc., Fluctuating loads will show poor efficiency; Extent of loading on the engine Type of governor;