When an incoming generator fails to synchronize with a running generator, it indicates a
synchronization problem. Several issues could be causing this problem. Here are a few
possible reasons:
1. Frequency Mismatch: The incoming generator may operate at a slightly
different frequency than the running generator. Generators need to match
their frequencies closely to synchronize correctly. Check the frequency
settings of both generators and ensure they are configured correctly.
2. Voltage Mismatch: A voltage mismatch between the two generators can
also prevent synchronization. The incoming generator should match the
voltage level and waveform of the running generator. Verify the voltage
settings, including magnitude, phase angle, and waveform, and ensure they
align.
3. Phase Sequence: The phase sequence, or the order in which the phases of
the generators' outputs are arranged, must match for synchronization. The
generators won't synchronize if the phase sequence is incorrect or reversed,
the generators won't synchronize. Verify the phase sequence of both
generators and ensure they are aligned.
4. Voltage Magnitude: If the voltage magnitude of the incoming generator is
significantly higher or lower than the running generator's voltage,
synchronization may fail. The voltage levels should be within an acceptable
range for synchronization to occur. Check and adjust the voltage settings as
necessary.
5. Synchronization Equipment or Controls: Issues with the synchronization
equipment or control system can also cause synchronization problems.
Faulty synchronizing devices, incorrect settings, wiring issues, or
malfunctioning control circuits can prevent proper synchronization. Inspect
the synchronization equipment, including synchronizers, synchronizing
relays, and associated control circuits, and ensure they function correctly.
6. Load Imbalance: A significant load imbalance between the two generators
can hinder synchronization. The load sharing between the generators
should be equal for successful synchronization. Check the load distribution
and adjust the load-sharing settings if necessary.
7. Communication or Timing Issues: Proper communication and timing signals
are crucial for synchronization. Check the communication links and timing
signals between the generators and the synchronization equipment. Ensure
they are appropriately connected, functioning, and synchronized.
In complex generator systems, it is recommended to involve qualified professionals or
electricians experienced in generator synchronization to diagnose and troubleshoot the
problem. They can perform detailed measurements, inspect the control systems, and
identify any specific issues preventing synchronization.
Is the incoming generator running at the appropriate speed? Is the running genset stable in
its output frequency? Is the incoming generator matched with the main bus bar Voltage?
Are the sensor circuits to the synchronizing module connected, OK?
Any of these issues can stop your incoming genset from synchronizing with the running set.
Check your governor response for good control of the prime mover to ensure that it’s able
to have the control necessary to match the frequency that the other unit is running at.
By the same token you need to be sure that the frequency of the running unit is stable
enough to allow the incoming unit to “catch” it. If the running genset is subject to wildly
fluctuating loads (and hence speeds), then the synchronizing module won’t be able to
match the speeds long enough to match the wave forms.
If the incoming generator Voltage is even a few Volts above or below what the main bus
Voltage is, the protection devices will hold it out and prevent synchronization since doing so
will result in a reactive power imbalance that can trip ACBs.
If the basics are all OK, and the relative speeds are close and well regulated, as well as the
AVRs being correctly matched so that the two Voltages are the same, then you could easily
have a sensor line failure. Check the sensor Voltages to the synchronizing module that
connects the main bus bar and the incoming genset before the ACB. If one of these are not
present, then the synchronizing module simply hasn’t got the inputs it needs to do the job.
It could also simply be just a broken synchronizing module.
