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Power topic #9015 | Technical information from Cummins Power Generation

Paralleling Dissimilar Generators:

Part 1 – An Overview
White Paper
By Gary Olson, Director of Technical Support

As a general rule, “you can parallel Generator compatibility

anything with anything,” as long as
Simply speaking, generator sets in a
the voltage and frequency are the paralleling system are compatible when
same at the point of interconnection. they have:
Of course, there are practical limits to Compatible engines
this statement, and a design requiring Compatible alternators
reliability and performance may compel Compatible load sharing control systems
a system designer to replace existing  ompatible interfaces to other monitoring
C
generator sets when they can’t be and control systems, including local and
remote monitoring, “first start” controls,
verified to be compatible with newer
manual controls, and load demand controls
equipment, or if the costs of driving
To a limited degree, systems can operate
compatibility into the older equipment successfully with less than completely
are not justified. This paper provides compatible equipment, but these
guidance on the issues that should be incompatibilities may result in the need for
added equipment in the system or limitations
considered and how typical problems in the flexibility or operation of the system.
can be addressed. Before any modifications to any existing
system are made, it is critical that the
equipment to be modified is fully tested to
verify that it can operate at full rated load
with proper voltage and frequency control.
If a machine can’t perform properly with a
dedicated load from a load bank, there is no
way that it will operate successfully in parallel
with other machines.

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paralleling JOB # CPE100154 DATE 11.5.10 InitIals date

CLIENT CUMMINS
Dissimilar CD Brien S.
JOB DESCRIPTION White Paper
generators AD
FLAT 8.5” x 11”
CW Don F.
BLEED 1/8”

3 FOLDED
FILE 100%
DS
AM Christie G.
COLOR CMYK
PM Katie D.
c M Y K CLIENT Cummins
 System-level issues “knows” the kW capacity of the generator sets available
on line can automatically compensate for the difference
Before looking at generator set compatibility, in sizes by using different sequencing when different
it’s worthwhile to consider several system-level combinations of equipment are available.
problems that come about due to use of dissimilar
How much difference in size is “practical”? That is a
generator sets.
matter of considerable discussion in the industry. We
If generator sets are of dissimilar sizes, there can be know that it’s technically possible to parallel anything
impacts on the system design. An emergency system with anything, but where it’s practical is less clear. In
with generator sets that have matching kW ratings general, you probably will have a manageable system
can support a higher first priority load than a system when the smallest generator set is no less than 30% of
that has generator sets with dissimilar kW ratings. the capacity of the largest generator set in the system.
For example, an emergency system with two 500 kW If there is a larger disparity in equipment sizes, it might
generator sets will handle a first priority load as large as be easier to make the larger machine bigger, and forget
500 kW. A system with one 750 kW generator set and about paralleling altogether.
one 250 kW generator set, while having the same total
It’s useful to note that there are often large kW size
power rating, should be limited to a 250 kW first priority
load, because if the first generator set closing to the bus differences in prime power applications, such as are used
is the 250 kW machine, any load greater than 250 kW in remote, isolated cities and towns. In those applications,
could cause it to be overloaded. loads during the daylight hours are often much higher
than in the evenings. A pair of 350 kW generator sets
When faced with the use of dissimilar-sized generator
may be running during the day, and only a 50 kW set
sets, some designers will insert bus isolation ties
running at night. This is less of an issue in prime power
between generator sets in order to prevent overloading
applications because the load profile does not quickly
on startup. This, however, sets up another series
of issues because of the added complexity in the change, and the systems generally have no automatic
sequence of operation and usually the need for more load management systems.
synchronizers in the system. Manual operation and
As a technical matter, the smallest power circuit breaker
failure mode effects are also more difficult to deal with
that we can provide is an 800 amp frame. So it can
as tiebreakers are inserted into a system.
be costly to parallel smaller generator sets. In those
Changes in sequence of operation may be necessary cases it’s possible to source 5-cycle operating molded
due to use of dissimiliar-sized machines. It is not case breakers for use in paralleling the generator.
advisable to design a system sequence of operation These breakers are smaller, available in fixed frame
contingent on synchronizing generator sets within configurations so less space is needed for the equipment,
10 seconds. Many manufacturers cannot provide
and less expensive, but they are available only from a
equipment that is certain to be paralleled in 10 seconds,
limited number of suppliers. In some cases motor starting
so in situations where local codes require service to
contactors might be used for paralleling applications
emergency loads within 10 or 15 seconds, the system
designer must choose between preventing smaller where smaller generator sets are used, but the contactors
machines from closing to the bus first (minimizing the must generally be protected by current limiting fuses for a
advantage of redundancy offered by many systems), safe design.
or making sure that first priority loads can always be
served by the smallest machine in the system.
Compatible engines
From a load shed perspective, the problem is less
The real power (kW) provided by a generator set
difficult, but still needs a bit of thought. If there is an
operating in parallel with others is a direct function
under-frequency condition on the bus, the system will
of engine real power output. Compatible engines
need to drop load. With dissimilar-sized machines,
can share load nearly equally, at all load levels, while
it is desirable to drop load in large enough steps to
operating at steady state load levels and during
relieve the 250 kW set in the event that the 500 kW
transient loading conditions. Conversely, if incompatible
unit becomes the unit that is not available. Cascading
engines are paralleled, load sharing problems can
type load shedding systems continue to drop load until
02 Power Topic #9015

occur, particularly on application or rejection of large

the system recovers, so they automatically deal with
load steps.
the problem via that mechanism. A system design that

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 As loads are added to a generator set, particularly reverse power to outside the recovery time for the
in large increments, the generator set frequency will slowest machine in the system. Do not address the
momentarily drop until the engine governor can drive issue by increasing the “Reverse Power” limit on the
more fuel into the engine to recover to its nominal generator set. This could desensitize the system to the
speed (frequency). The amount of speed drop and the point that reverse power protection is lost.
recovery time are a function of the inertia in the rotating
components of the system and how fast the governing
and air intake systems can increase the fuel rate in the
Compatible alternators
engine. The generator set’s recovery rate is determined Alternators are compatible if they can operate in parallel
by the type of governing system, the engine’s fuel and without damaging or disruptive neutral currents flowing
air intake system designs, and the engine’s combustion between them. Depending on the generator set’s
cycle (two-stroke or four-stroke). temperature rise characteristics, age and insulating
ratings, neutral current flow between generator sets
Load sharing during transient conditions is a concern
is not necessarily damaging, but neutral currents
because differently sized machines often accept and
can cause disruption in protective relay operation,
reject load with different levels of ability. For example,
particularly for ground fault sensing.
consider a paralleled 250 kW and a 500 kW generator
set. Application of a 250 kW load on a 250 kW Neutral current flow between generators occurs when
generator set will result in a voltage dip of approximately the voltage between the two machines is different. The
25%, and a recovery time of 3 seconds. For the
voltage difference can occur because of inaccuracies
500 kW generator set, a 500 kW load results in a
in the kVAR load sharing adjustments, or because
voltage dip of 30%, and a recovery time of 5 seconds.
of differences in the voltage waveform shapes due
So if a 750 kW load (a full load step) is applied on the
two machines, or drops 750 kW in one step from the to differences in alternator voltage harmonics as is
two machines, they will not share loads equally during illustrated in Figure 1.
the transient period. It is possible to have the system
exposed to potential overcurrent conditions on the VOLTAGES PRIOR TO CONNECTION
OF TWO DISSIMILAR MACHINES
faster machine or nuisance reverse power faults on
load rejection. RESULTANT CURRENT FLOW AFTER
PARALLELING (MAGNIFIED)
At lower load levels, voltage and frequency transients
are lower, and recovery times are shorter, so as load
step size drops, it eventually gets to the point that
transients of a specific level are very similar between
machines. This means that dissimilar transient
performance of the machines can be dealt with by
adding and shedding loads in smaller steps than might
be used in a system that has all the machines of the
Figure 1 - Whenever there is even an instant where the voltage
same size. A system designer can compare the single between the two sources is different, current will flow between the
step load pickup and load rejection performance of the machines.
various machines in the system to determine if there
is a potential problem with engine compatibility. When If an operating system exhibits symptoms of
that is done, actual assembled generator set test data incompatibility between alternators (such as current
should be used in the evaluation, not just alternator flow that can’t be adjusted out by kVAR load sharing),
voltage dip or engine (alone) transient performance. As a harmonic analysis test of the neutral current flow
a general rule, there will be no negative impacts due to between the machines when operating with balanced
difference in engine performance if the transient load linear load (or even no load) can be conducted. If the
steps are less than 25% of the rating of the smallest fundamental frequency of the current is the same
generator set in the system. as the system operating frequency, the current flow
Nuisance reverse power trips on load rejection can is a result of inaccurate kVAR load sharing. If the
often be addressed by increasing the time delay on fundamental frequency is 150 hertz or greater, the
current flow is almost certainly due to alternator
03 Power Topic #9015

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 incompatibility, and a decision is needed as to how to  onnect neutrals of like machines only, and prevent
C
deal with it. Harmonic neutral current flow is caused by the dissimilar machines from being the first to close
differences in the voltage waveform shape between two to the bus.
(or more) paralleled machines.  dd neutral contactors to the switchgear to connect
A
Alternator designers can control the harmonics the neutral only on the first unit to close to the bus.
This, however, introduces several other potential
produced in an alternator by manipulating several
problems and is not normally recommended.
design factors, the most important of which is alternator
pitch. The pitch of a generator set is a design parameter Install reactors in the neutral leg of each generator
that can be used to optimize the generator set set to limit current flow at third and higher order
waveform shape and minimize costs. The pitch refers frequencies. Reactors can be tuned to specific
to the mechanical design characteristic of a generator frequencies that are the biggest problems.
set. It is the ratio of the number of slots enclosed by  ompensate for the incompatibility by over-sizing the
C
each coil to the number of winding slots per generator neutral conductor, and derating the alternators.
set pole. Alternators that are identical are obviously  he designer may allow system operation with the
T
compatible. Similarly, alternators that have 2/3 pitch will neutral current and compensate by derating the
have waveforms that are compatible for paralleling with generator set.
each other and/or with the utility.
More information on alternator compatibility can be
found in our white paper: PT-9016 Paralleling Dissimilar
Compensating for Generators: Part 2 — Compatible Alternators.
pitch differences
When faced with a requirement to parallel dissimilar Compatible load sharing
generator sets, a system designer has several options
to avoid harmonic problems associated with generator
control systems
set incompatibility: In a paralleled arrangement, the voltage and frequency
If possible, require that new equipment be identical outputs of the generator sets are forced to exactly the
to existing equipment. This may require replacement same values when they are connected to the same
of one or more alternators in the system. Considering bus. Consequently, generator set control systems
that the effective life of an alternator is approximately cannot simply monitor bus voltage and speed as a
25 years in a standby application, and that engines reference for maintaining equal output levels. If, for
often be fully functional at that age, this is not an example, one set operates at a higher excitation level
uncommon choice. Requiring a 2/3 pitch on all than the other sets, the reactive load will not be
alternators, even if they are not paralleled, makes shared equally.
them compatible for future paralleling. Replacing
alternators is more practical at line voltage level than Similarly, if a generator set is regulated to a different
at medium and high voltages, due to significantly speed than the others, it will not share kW load
higher cost for higher voltage machines. properly with other generator sets in the system. Each
 se a 3-wire primary distribution system. By avoiding
U generator set in the system has two active control
a solid neutral connection, there is no path for the systems always in operation: the excitation control
neutral current flow, so the most disruptive problem of system regulating voltage and the fuel control system
the incompatibility is removed. Note that the neutral of regulating engine speed. Generators can be sharing
the dissimilar machine must not be bonded to ground kW load and have problems sharing kVAR load, and
when other machines are connected. Harmonic vice versa.
currents will still flow in the phases between the
generators, but will be less apparent, and the system So real power sharing (expressed as kW) depends
will not be hampered with problems associated with on speed matching between the generator sets and
high neutral current flow. Transformers may be used fuel rate control; reactive power (expressed as kVAR)
to develop necessary neutral connections for single- is primarily dependent upon voltage matching and
phase loads.
04 Power Topic #9015

excitation system control between the generator sets.

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 Although it is sometimes possible to integrate systems As illustrated in Figure 2, droop governing or voltage
of different manufacturers, generator set governors regulation allows the engine speed (measured in Hz)
and load sharing controls should be of the same or alternator voltage to decline by a predetermined
manufacturer to avoid conflicts in responsibility for percentage (typically 3%) of the output range as load
increases. Identical speed and voltage drops result in
proper system operation.
equal load sharing between paralleled generator sets.
Several types of load sharing control are available:
The same practices as described here can be applied
 roop governing and voltage regulation (reactive
D to the voltage regulation system of the generator sets
droop compensation) in a system. Var load sharing via droop is often termed
“reactive droop compensation.”
Isochronous kW load sharing
Cross current compensation for kVAR load sharing Common droop settings for frequency and voltage
can be different and are typically in the range of
Isochronous Voltage kVAR load sharing
3–5% from no load to full load. The voltage variations
that occur due to droop operation at this level are not
Droop load sharing significant in isolated bus systems, but the frequency
variations that occur can be disruptive to operation of
Droop governing and voltage regulation systems have some loads, especially in emergency/standby systems
been historically used for isolated bus paralleling, where the load can vary considerably over time.
because they allow proper load sharing between any Droop load sharing is common on attended prime
two or more generators operating on an isolated bus, power applications.
as long as the generators can be set up to droop
frequency and voltage at the same rate, and can be Droop governing can generally be used for generator
controlled to stable frequency and voltage values. loading control in single generator set-to-utility
paralleling systems because the utility frequency is
100 usually very constant. However, reactive droop is not
95% effective for utility paralleling due to the greatly varying
DROOP voltage level at any point in a utility distribution system
ISOCHRONOUS
as the load on the system changes. Var/power factor
controllers should be used when generators are
PERCENT HZ OR VOLTS

paralleled to a utility source.

50

0 100
PERCENT LOAD
Figure 2 - Droop governing.

05 Power Topic #9015

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 LOAD ADD/SHED START
COMMANDS COMMANDS

PLC BUS BUS

PROT METERS

START COMMAND, ALARM DATA

MASTER CONTROL

LOAD SHARE DATA

ALARM ALARM

EC EC

ENGINE

ENGINE
GOV GOV

METER PROT SYNC ILS METER PROT SYNC ILS

AVR GEN AVR GEN

PARALLEL CONTROL PARALLEL CONTROL

CB CB

POWER
TO
LOAD
Figure 3 - A block diagram of a simple isolated bus paralleling system showing interface of generator sets, paralleling functions and master control system.
Note that the only interface between the generator sets is the load sharing signals.

Isochronous kW and kVAR Analog control systems are often faster responding
than digital communication/control systems and can
load sharing often be made to be compatible between different
manufacturers. Cummins manufactures an analog load
Isochronous load sharing control systems are active
sharing interface module (ILSI) that can be used for
control systems that calculate the percentage of real
interface of Cummins PowerCommand® systems with
and reactive load on a specific generator set, compare
other load sharing controls that use analog signals.
those values to the percentage of real and reactive
Digital communication/control systems generally
load on the system, and then provide control to the
have less susceptibility to external interference than
fuel and excitation system of the generator to drive
analog signals, but every supplier has a different
the percentage of load on the generator to the same
communication algorithm that makes it difficult to add
value as the percentage of load on the system. Load
dissimilar equipment to an existing system.
sharing is critical to paralleling compatibility because
the load sharing communication is the only point where
generator controls interact with each other when Cross current compensation
operating on an isolated bus.
Cross current is a flow of electrical current between
To provide load sharing functions, each generator set generator sets that is caused by dissimilar excitation
in the system must have controls that will calculate the levels in those sets. Cross current compensation is a
total percent of kW and kVAR load on the machine, and term describing operation of paralleled generator sets
then have a means to compare that value to that of the
without intentional voltage droop. This is achieved by
system as a whole. Several approaches are available
insertion of a droop current transformer (CT), usually on
in the marketplace to provide this interface. In general,
“B” phase of each generator, and interconnecting the
they can be broken into two large groups:
CTs to provide an identical voltage bias to each AVR in
Systems that use analog signals for load sharing the system. The system works best when the voltage
 ystems that use digital communication signals for
S regulators are all of the same manufacturer and model.
load sharing (such as CAN, RS485 or Ethernet) Not all voltage regulators work together in this mode,
06 Power Topic #9015

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 so the best planning practice is to make sure that all the To prevent out-of-phase paralleling on energizing a
voltage regulators in a system that uses cross current dead bus, most systems provide a means to positively
compensation are all identical. select the first generator set to close to the bus and
prevent other machines from closing until the bus
If system operation in isochronous condition is desired,
is energized and oncoming machines are properly
the best practice is to arrange the equipment so that
all generators in the system use the same load sharing synchronized. The devices and practices for providing
control system. Other alternatives for paralleling with this function are different between suppliers, and
dissimilar load sharing control systems are discussed generally not compatible with one another.
in our document PT-9017, Paralleling Dissimilar
A system designer can deal with this by preventing
Generators: Part 3 – Load Sharing Compatibility.
dissimilar machines from closing to the bus until at
least one other machine has closed. This is a viable
Compatibility with other alternative if there are multiple machines available with
control systems compatible First Start systems, so that it is likely that
the bus will be energized without the “odd” machine
Individual generator sets in a paralleling system may coming on line. It’s also possible that a PLC-based
interface to each other and the balance of the facility in program can duplicate the logic of one of the suppliers
a number of ways, including: to get this detail covered.
 enerator sets must have a means to determine
G
which generator set will close to the bus first in a Alarm and status information
“black start” (first start) situation.
Alarm and status information on generator sets has
 enerator sets often provide status information
G
traditionally been provided with discrete (contact-
to a system master control, for the purpose of
based) signals that operate a relay and light a lamp if
displaying data, allowing the master control to control
there is a specific alarm or status condition present.
system power capacity, and for central system
These signals are available on nearly any generator set
load management.
and are compatible with most systems, so they don’t
 enerator set may be monitored by a facility
G represent serious issues, although there is a risk of
monitoring system, or by an external monitoring incompatibility if planning is not carefully done.
system, such as for service contract facilitation.
Modern engines and the generator sets they are built
In general, these communication tasks are handled by with can have literally hundreds of alarm and status
commonly available communication practices such as conditions, and the traditional conditions annunciated
discrete signals or by digital communication such as are not necessarily the most common or useful
RS485/Modbus1 register maps. So the main concern in information to pass to the system operator. AC data
dealing with them is to simply plan for them carefully. and engine operating data are also useful in remote
monitoring. Since most generator sets now are built
Picking the first generator to with processor-based controls, most of this type of
information is available via both digital communication
close to the bus mechanisms and traditional relay-based formats. The
First Start control is handled in different ways by designer simply needs to decide what information is
different vendors. Some suppliers simply use a dead needed and specify what means are to be provided
bus sensor for each genset synchronizer, which allows to pass the information to the user.
each paralleling breaker to close to the bus if voltage is
Options for remote monitoring include traditional
not sensed on the bus. This is a risky practice because
alarm panels, alphanumeric displays, and
it is quite possible that multiple generators can reach a
touchscreen displays. Digital information is also
decision to close to the bus at the same time, resulting
easy to transfer into web-based monitoring systems
in out-of-phase paralleling of the machines.
and text-messaging systems.
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 About the author
Gary Olson graduated from Iowa State include research relating to on-site power
University with a BS in mechanical engineering applications, technical product support
in 1977, and graduated from the College of for on-site power system equipment, and
St. Thomas with an MBA in 1982. He has been contributing to codes and standards groups.
employed by Cummins Power Generation for He also manages an engineering group
more than 25 years in various engineering and dedicated to the design and development of
management roles. His current responsibilities next-generation power systems.

Recommendations
When paralleling dissimilar generator sets, a
designer should:

 erify that the existing generator set can carry full load
V
with good voltage and frequency regulation.
 eview the transient performance of all the generator
R
sets in the system and verify that the load steps
(particularly load rejection) of all the gensets will not
result in objectionable levels of reverse power.
 erify that the pitch of all alternators is the same.
V
Specify 2/3 pitch on all generator sets to avoid
problems with this. Take mitigating steps if dissimilar
alternators cannot be avoided.

In addition:

 or emergency/standby applications, load sharing

F
controls (both kW and kVAR) should all be of the
same manufacturer and model. Droop control may
be suitable for some prime power applications and
isolated bus kVAR load sharing.
 ttention should be given to the specific control
A
interfaces to system master controls and facility
management systems monitoring the generator bus.
In general, these can be made to work in nearly
every case, but it cannot be assumed that they will
work without checking and verifying that the proper
equipment is in place.

1
Modbus is a registered trademark of Group Schneider.
08 Power Topic #9015

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and Cummins are registered trademarks of
Cummins Inc. “Our energy working for you.™” is a
trademark of Cummins Power Generation.
PT-9015 (8/10)

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