Professional Documents
Culture Documents
1
Electrical Engineering Aspects of
Integrating Industries with Captive
Generation Sets with the Grid
Power Research & Development Consultants Pvt. Ltd.
Power Research & Development Consultants Pvt. Ltd.
2
Scenario in Indian Grid in early 60s
Generation more than demand
Good Quality Voltage
Uninterrupted power supply to industries
Result
No captive generation in the industries designed in those
days.
Introduction
Power Research & Development Consultants Pvt. Ltd.
3
Current Scenario
Voltage variations
Frequent interruptions
Power cuts - scheduled /unscheduled
Result
Captive generation in most of the industries
(Both old and new).
Introduction
Power Research & Development Consultants Pvt. Ltd.
4
Advantages of Captive Generation
Reliable and uninterrupted power supply
Power supply meeting both quality and quantity
Disadvantages
Increased production cost
Separate maintenance & operational personnel
Introduction
Power Research & Development Consultants Pvt. Ltd.
5
Modes of operation
1. Synchronized mode (Synchronized with the grid)
* Varying or cyclic loads wherein grid support is essential
* Arc furnace loads
* Rolling mills
* Processes where no interruption of power is envisaged
* Starting of large motors
2. Islanded / Isolated mode
* Constant load
* Interruption of power for short duration acceptable
Power Research & Development Consultants Pvt. Ltd.
6
Electrical aspects
1. Steady state requirements
2. Fault level
3. Generator control
4. Protection
5. System Stability
6. Harmonics
7. Metering
8. Special considerations
Power Research & Development Consultants Pvt. Ltd.
7
Plant 11 kV or 33 kV
Grid 66 kV or 110 kV or 220 kV
Steady state requirements
Incoming transformer tap (OLTC)
For varying grid
voltage, to have
smooth operation, the
transformer should be
OLTC. To have
sufficient voltage at
the in-plant generator
terminal bus, to have
proper excitation, tap
requirement is 15%
to +10%. 15% to
5% is also acceptable.
Power Research & Development Consultants Pvt. Ltd.
8
Fault level
In new plants, breakers are designed for
higher fault levels.
But in old plants, breaker fault capability is
less.
Hence for old plants, captive generations are
usually not paralleled and not synchronized
with the grid. i.e., always operated in isolated
mode.
However, with open access, strong grid, now a
days parallel connection with grid is
acceptable.
Power Research & Development Consultants Pvt. Ltd.
9
Remedial measures
Replace the breaker
Cost involved
Shutdown
Series Reactors
Degradation of steady state voltage
performance
Reactive power support
Power Research & Development Consultants Pvt. Ltd.
10
Generator Control
Automatic Voltage Regulator (AVR) Fast acting is preferred if
the grid voltage fluctuations are more due to neighboring
loads.
Governor Requires special control circuit to change over
from constant power mode (in synchronization with the grid)
to constant frequency mode (isolated operation).
Reason 50 MW generators, 4% drop
Change in grid frequency 0.5 Hz
Change in power - 12.5 MW
Irrespective of grid frequency, constant power of 50 MW
Power Research & Development Consultants Pvt. Ltd.
11
Protection
Over current relays need to be directional
Simple reverse power relay at the grid tie was
adequate when only import is considered. But now since
both import and export are possible, reverse power relay
will not meet the requirement
Smooth change-over or plant isolation from grid
(without loosing plant generation) necessitates under
frequency & over frequency protection schemes
Distance relay on the transmission line only at grid
end in most cases. Now it requires at the plant end also.
Pilot relaying scheme can be envisaged for short
distances
Power Research & Development Consultants Pvt. Ltd.
12
System Stability
System becomes more stable with added
availability of synchronising power and
reactive power support.
Generator performance for grid fluctuations
and small signal oscillations need to be
studied.
A good islanding relay to safeguard the CPP
units for grid disturbance is required.
Power Research & Development Consultants Pvt. Ltd.
13
Harmonics
Integration of captive generation with the
grid implies industrial plant is in parallel
with the grid.
Harmonic injections from the plant
should be maintained within the acceptable
limits.
Hence harmonic filters should be provided.
At times, grid harmonic may also affect the
CPP generators
Power Research & Development Consultants Pvt. Ltd.
14
Metering
Import meter needs to be replaced by
import and export meter.
Modes of tie-ups
Banking
Wheeling
Selling
Power Research & Development Consultants Pvt. Ltd.
15
Interconnection at what voltage level?
This solely depends on
Power to be exported/imported
Number of outlets available
Number of consumers in the vicinity and
Distance involved.
Typically,
POWER VOLTAGE LEVEL
50 200 MW 220 kV
10 50 MW 66/110/132 kV
05 10 MW 11/33 kV
Power Research & Development Consultants Pvt. Ltd.
16
Interconnection at what Capacity?
Technically it is possible
Cost aspects need to be worked out
Fuel cost
Additional capital investment
Procedures
Confidence in electricity board
Power Research & Development Consultants Pvt. Ltd.
17
Conclusions
Considering electrical aspects, it is possible
to integrate the captive generation with
the grid
Protection and controls are to be provided
in consultation with
Equipment manufacturer
Power system analyst
Special studies are to be conducted, on
case to case basis.