Industrial generators can be synchronised for parallel operation.

The simple answer is yes, industrial generators can be synchronised for parallel operation, and this practice is quite common in various industries.

Synchronising generators involves connecting multiple generators to work together as a single unit, which can provide several benefits such as increased reliability, efficiency, and flexibility in power supply.

What is Generator Synchronisation?

Generator synchronisation means aligning the output of multiple generators so they can operate together on the same electrical grid.

For generators to run in parallel, they must have the same voltage, frequency, phase sequence, and phase angle. Once synchronised, these generators share the load, ensuring a steady and reliable power supply.

Why Synchronise Generators?

Increased Reliability: If one generator fails, the others can continue to provide power, reducing the risk of a complete power outage.
Enhanced Efficiency: Load sharing among generators can optimise fuel consumption and reduce operational costs. Each generator operates at its optimal capacity, which can be more efficient than running a single generator at a higher load.
Maintenance Flexibility: With multiple generators in parallel, you can perform maintenance on one generator without shutting down the entire power system. This is especially important in industries where continuous power is crucial.
Scalability: As power demand increases, additional generators can be added to the system without significant changes to the existing setup.

How is Synchronisation Achieved?

Synchronisation involves several key steps:

Matching Voltage: The output voltage of each generator must be the same. This is usually controlled by adjusting the excitation of the generators.
Matching Frequency: The frequency of the electrical output (typically 50 or 60 Hz) must be the same for all generators. This is achieved by controlling the speed of the engines driving the generators.
Matching Phase Sequence: The order of the phases (A, B, C) must match for all generators. Incorrect phase sequence can cause severe damage to the electrical system.
Matching Phase Angle: The phase angle of the voltage waveforms must be aligned. This ensures that the generators’ outputs are in sync and can combine smoothly.

Equipment Used in Synchronisation

Several devices and systems are used to synchronise generators:

Synchronisers: These devices automatically match the voltage, frequency, and phase angle of the generators.
Paralleling Switchgear: This equipment controls the connection of multiple generators to a common bus and manages load sharing.
Automatic Voltage Regulators (AVRs): AVRs adjust the excitation of the generators to maintain consistent voltage levels.
Governor Controls: These controls manage the engine speed to maintain the correct frequency.

Steps for Synchronising Generators

Preparation: Ensure that all generators are properly maintained and operational. Check fuel levels, oil, and other essential components.
Initial Setup: Start the first generator and bring it to the desired voltage and frequency. Connect it to the electrical bus.
Synchronising Additional Generators: Start the next generator and bring it up to speed. Use the synchroniser to match its voltage, frequency, and phase with the first generator. Once matched, connect it to the bus.
Load Sharing: Adjust the load-sharing controls to ensure each generator takes on an appropriate share of the load.

Challenges and Considerations

Complexity: Synchronising generators requires precise control and monitoring. Advanced equipment and skilled personnel are essential.
Costs: The initial investment in synchronising equipment can be high, but the long-term benefits often outweigh the costs.
Harmonics: Multiple generators can introduce harmonic distortions, affecting power quality. Proper filtering and design can mitigate these issues.

Can industrial generators be synchronised for parallel operation?

Synchronising industrial generators for parallel operation is a practical and beneficial approach for ensuring a reliable and efficient power supply.

By carefully matching voltage, frequency, and phase, multiple generators can work together seamlessly, offering flexibility and scalability to meet varying power demands.

While the process involves some complexity and cost, the advantages in reliability, efficiency, and maintenance flexibility make it a worthwhile investment for many industries.