Critical-Power Automatic Transfer Systems - Design and Application
Critical-Power Automatic Transfer Systems - Design and Application
Critical-Power Automatic Transfer Systems - Design and Application
1. INTRODUCTION
An important requirement of mission-critical electric power distribution systems is the need for
automatic operation. In particular, the rapid and reliable transfer of the system from one power
source to another during certain system events is crucial to achieving the reliability goals for such
system and the facility it serves. However, the design of such an automatic transfer system is alltoo-often considered less important than many other aspects of the over-all power system
design. The results of this can be far-reaching and, in some cases, catastrophic with respect to
the reliability of the system.
This paper outlines the design considerations for automatic transfer in the mission-critical power
environment, and gives recommendations as to how these considerations can be reliably
implemented into an automatic transfer system.
2. BACKGROUND
2.1.
Fig. 1
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2.2.
Voltage Levels
The choice of distribution voltage in a facility is largely dependent upon the size of the facility and
its power system. In many cases, a medium-voltage (2.4 69kV) service is required by the utility
for a given ampacity service. However, most utilization equipment requires voltage levels in the
low-voltage range (up to 600V). The information given herein is equally applicable to automatic
transfer systems for low- and medium-voltage systems.
Where multiple automatic transfer systems exist at different voltage levels, some coordination
between them is typically required in order to prevent unwanted transfer operations. This will be
discussed herein.
2.3.
The choice of power system distribution topology is the first line of defense against critical-load
outages. In the context of automatic transfers, the most common arrangement is the secondaryselective or main-tie-main arrangement. One implementation of this arrangement is as shown
in Fig. 2:
Fig. 2
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a.)
Fig. 3
b.)
It should be noted that the main-tie-main topology is also commonly used at the medium-voltage
level.
Other arrangements exist, however none are as popular in the critical-power distribution
environment as the secondary-selective main-tie-main and its variants. One other arrangement,
however, has been used with great success is the ring bus, as illustrated in Fig. 4:
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Fig. 4
The ring bus arrangement allows the flexibility of supplying multiple loads using multiple busses.
It is most often used at the medium-voltage level, and usually in a closed loop arrangement with
all of the bus tie circuit breakers closed.
A variation on the ring-bus is the primary loop arrangement shown in Fig. 5:
Fig. 5
A primary loop arrangement typically uses load-interrupter switches for switching on the loop, and
is more economically justifiable than a full ring-bus system. Typically, the loop is operated in an
open-loop arrangement, but still gives the ability to supply all loads from either side of the loop.
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Fig. 6
2.4.
On-Site Generation
As mentioned above, utility power typically has 99% - 99.9% availability. In a given year, this
equates to 9 90 hours per year when utility power is not available. For this reason, it is
essential that an alternate source of power be available to power the system when utility power is
unavailable. Typically, this alternate source of power is in the form of standby engine-generator
sets, typically diesel-powered.
The interface of generation with the system can be in one of several forms. One form is grouped
generation/single transfer, an example of which is shown in Fig. 7:
Fig. 7
As the name implies, the generation is grouped (electrically, if not always physically) onto one
bus, and the critical loads can be transferred to generator power using one circuit breaker. Care
must be taken not to block-load the generators to a higher level than will produce acceptable
system performance (frequency and voltage excursions will occur on block-loaded generators,
the severity of which is dependent upon the engine-generator set design and the level of block
loading). Also, the single bus tie breaker is a single point of failure which may not be acceptable.
Multiple generators are provided, usually at least one more than is necessary to supply the entire
load (i.e., N+1), due to engine-generator set reliability concerns.
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Fig. 8
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Fig. 9
2.5.
Distributed Generation
As stated above and shown graphically in Fig. 1, computer loads are extremely sensitive to
power system anomalies. As has also been stated, bringing backup generation on-line can take
several seconds far too long to allow continuity of operation for these types of loads. For these
two reasons, uninterruptible power supplies are used to provide continuous, conditioned power to
these loads.
UPSs use stored energy, usually chemical energy in the form of batteries or mechanical energy
in the form of a rotating flywheel, and use it to bridge the gap from the time the normal source of
power (i.e., the utility) fails and the time the alternate source of power (i.e., the standby
generators) can be brought on-line. In addition, many UPS topologies provide power
conditioning, further isolating the computer loads from disturbances on the system. However, the
UPS stored energy source cannot operate indefinitely, and typically requires re-charging from the
system normal or alternate power source.
There are several UPS topologies currently on the market and a general discussion of these is
beyond the scope of this paper, however UPSs are important in the over-all context of automatic
transfer systems.
2.6.
Using the basic building blocks of utility power, system topology, on-site generation, and
uninterruptible power supplies, the basic role of the automatic transfer system may now be
defined. Simply stated, the role of the automatic transfer system is to provide the automatic
transfer of power for its associated load group from a normal power source, such as a utility
service, to an alternate power source, such as standby generation, in the event the normal source
fails. This is shown diagrammatically in Fig. 10:
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Automatic
Transfer
System
Normal
Power
Source
Alternate
Power
Source
Switchgear
UPS
Critical
Loads
Essential
Loads
3. OPERATIONAL REQUIREMENTS
3.1.
To fully illustrate the operational requirements of a typical automatic transfer system, a more
detailed representation of the system is required. For this purpose, the main-main arrangement
of Fig. 3b.) used, but with the details of the automatic transfer system shown:
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Normal Power
Source
(Utility)
Alternate Power
Source
(Generator)
e
Gen
CB-UM
Opening/Closing Control
Circuit Breaker Status
Automatic
Transfer
Logic
User-Adjustable
Parameters
rato
r Sta
on
itiati
rt In
Opening/Closing Control
CB-GM
User
Interface
3.2.
Modes of Operation
An essential requirement of any automatic transfer system is the ability to have different modes of
operation. In a given mode of operation, the transfer system will respond in a given way to
changing system conditions. For a different mode of operation, the transfer system will respond
differently. Two basic modes of operation, which any automatic transfer system must have, are:
1.) Manual Mode
2.) Automatic Mode
In the manual mode, the automatic transfer system does not perform any automatic operations,
i.e., it does not respond to changing system conditions. All circuit breaker operations must be
manually performed. Conversely, in the automatic mode of operation all operations, with a few
emergency exceptions, are automatic, and the system will respond automatically to changing
system conditions.
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3.3.
Initiation of Transfer
In the automatic mode, the transfer system must be able to react to source failure by initiating
transfer. For this purpose, it is necessary for the mode logic to know the condition of the normal
and alternate power sources. This is typically accomplished via undervoltage (device 27) and
negative-sequence voltage (device 47) relays, as shown in Fig. 11. Frequency relaying is usually
not required for utility sources as the frequency is quite stable, and not affected by changing load
conditions within the facility. For standby generators, however, although they are typically
controlled via isochronous governors there is a limit to the amount of power (and to sudden
changes in power) that they can supply without frequency changes. Also, at the beginning of the
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3.4.
Dead-Bus Considerations
Once a transfer operation has been initiated and the system has been disconnected from its
normal source of supply, a suitable time delay must be given to allow the residual voltage from
spinning motors to decay before the system is transferred to the alternate source. This time
delay is known dead-bus time, and it is vital that this be taken into account in the transfer scheme
design. If this is not done, there is a significant risk of both shaft and winding damage to
connected motors due to the energy transfer that can occur. For the example system of Fig. 11,
this will almost always be inherently be accounted for due to the generator start-up time, however
the logic should incorporate controls to insure this. In general, any time a system bus is deenergized due to automatic transfer action a dead-bus delay should be coded into the transfer
logic. Typical dead-bus delays are 2 5s.
3.5.
Generator Starting
For the example system of Fig. 11, a signal is provided to initiate generator starting. In general,
this will be a requirement any time one of the sources of power is a generator or generators,
unless the generator(s) is used for cogeneration as well as standby power. Typically, this signal
is a contact closure; once the contact is closed the generator(s) will start up and will run until the
contact is opened, at which time the generator will begin a cool-down cycle. Other variations
exist, however in general the management of the generator cool-down cycle should remain under
control of the generator(s) control system rather than the automatic transfer system.
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3.6.
Completion of Transfer
After the alternate source is available and the required dead-bus delay has expired, the transfer
system must close the alternate-source circuit breaker to supply the system from the alternate
source. In the example system of Fig. 11, the alternate-source circuit breaker is CB-GM. For a
main-tie-main system as shown in Fig. 2, the secondary bus tie circuit breaker would be the
circuit breaker that is closed. For a main-tie-tie-main system such as shown in Fig. 3b.), one of
the bus tie circuit breakers would normally remain closed all of the time, and the second tie circuit
breaker would be the circuit breaker that is closed to complete the transfer.
3.7.
The normal source, when it returns, typically starts a timer in the automatic transfer system. This
timer is present so that re-transfer will not occur until the normal source has been shown to be
stable. The time delay is known as a return of source time delay and is typically set from 5 15
minutes. Once the time delay has expired the return to the normal operating condition may be
open- or closed-transition, and may be manually or automatically initiated.
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3.8.
Unusual Conditions
Unusual conditions can occur during the automatic transfer process. For example, the normal
power source could fail, only to be restored during the dead-bus time delay before the alternate
source is connected to the system. How the automatically transfer system responds during such
conditions has traditionally been a function of the skill of the transfer system designer and the
requirements of the facility. The basic philosophy for automatic transfers in mission-critical
environments is to transfer the system if the condition of the normal source is in doubt, so long as
the alternate power source is known to be available and it is safe to do so, and most automatic
transfer systems for these environments are designed with this goal in mind.
4. EQUIPMENT SPECIFICATION
Although the basic operational requirements of any automatic transfer system are as given in
section 3 above, the equipment which is used to implement the automatic transfer system can
vary. The following is a list of commonly encountered variations regarding the automatic transfer
system equipment.
4.1.
Switchboard or Switchgear?
The power equipment used to facilitate the transfer, for low-voltage systems, is commonly either
a UL 891 switchboard or ANSI C37.20.1 low-voltage power switchgear. Which is used is
dependent upon the system design and where in the over-all power system the equipment is
located, however the following general guidelines apply:
1.) For automatic transfer higher in the system (closer to the service), ANSI low-voltage
switchgear is generally preferred due to is compartmentalization and the use of drawout
low-voltage power circuit breakers, which have short-time withstand capabilities. An
alternative is a hybrid UL 891 switchboard which uses drawout insulated-case circuit
breakers with characteristics similar to low-voltage power circuit breakers, but with less
compartmentalization.
2.) For automatic transfer lower in the system (farther from the service), a UL 891
switchboard may suffice. However, drawout circuit breakers should be considered even
if a UL 891 switchboard is used. Lack of short-time withstand on molded-case circuit
breakers is a big factor here.
4.2.
Logic Platform
The automatic transfer logic may be supplied by either discrete control relays or a programmable
logic controller (PLC), as shown in Fig. 12. In times past, this was generally a choice of flexibility
(the PLC) vs. robustness (discrete relays). In recent years, however, PLCs have undergone
significant improvements in reliability and robustness, to the point that they are now the preferred
method for implementing automatic transfer scheme logic.
The flexibility given by the use of PLCs lies in the fact that the automatic transfer logic is coded
into software, rather than hard-wired. This makes some on-the-fly changes, if required, possible
without hardware or wiring modifications to the equipment. It also allows more complex decisionmaking logic to be implemented without excessive wiring. Discrete control relays, on the other
hand, must be re-wired to make changes to the automatic transfer logic, and more complex logic
generally requires more control relays and wiring.
Another advantage of a PLC is its ability to communicate digitally with external devices. This
makes more sophisticated user interfaces possible, as will be discussed below. It also allows
remote access to the transfer system if required.
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4.3.
Interlocking is the restriction of operation of devices, usually for safety reasons. For an automatic
transfer system, the most common interlocking required is interlocking to prevent out-ofsynchronism paralleling of power sources (or prevention of paralleling at all in many cases).
When the automatic transfer system logic is provided by a PLC, this interlocking may be
implemented in a hard-wired fashion, that is, outside of the PLC or as part of the PLC program.
In general, use of hard-wired interlocking is preferred, to allow an extra measure of safety should
the PLC fail.
Similarly, manual control for automatically operated circuit breakers may be implemented in a
hard-wired fashion or via the PLC. It is generally recommended that at least the circuit breaker
tripping function be implemented outside the PLC. Manual control for automatically-operated
circuit breakers is generally implemented via an external control switches, with the manual close
control (and often trip control) on the circuit breaker access-restricted via a cover to force use of
these control switches.
4.4.
User Interface
This is the most customizable part of the automatic transfer system equipment. In general, two
options are available: discrete controls or touch screen.
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5. COMMON MISCONCEPTIONS
Several common misconceptions regarding automatic transfer systems exist. Some of these are
addressed here.
5.1.
This may or may not be true, but in general if more than one automatic transfer scheme is
present, the farther downstream it is, the less complex it has to be. For example, consider the
system of Fig. 15:
Automatic
Transfer
System
Automatic
Transfer
System
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6. SUMMARY
In this paper, many aspects of automatic transfer systems for the critical power environment have
been examined. In general, the manufacturers experience with these types of systems, along
with proper specification, are the keys to successful transfer system design and implementation.
When properly designed and implemented, automatic transfer systems provide a vital function in
the reliable operation of critical power systems. Working in conjunction with alternate power
sources and UPSs, automatic transfer systems help to insure that critical system loads receive
the reliable power they require in order to function.
7. REFERENCES
[1]
ITI (CBEMA) Curve Application Note, The Information Technology Industry Council,
Washington, DC, 2000
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