Electrical Engineering Aspects of Integrating Industries With Captive Generation Sets With The Grid

Power Research & Development Consultants Pvt. Ltd.
1
Electrical Engineering Aspects of
Integrating Industries with Captive
Generation Sets with the Grid


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

3
Current Scenario

Voltage variations
Frequent interruptions
Power cuts - scheduled /unscheduled

Result

Captive generation in most of the industries
(Both old and new).
Introduction

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

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

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

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.


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.

9
Remedial measures
Replace the breaker
Cost involved
Shutdown
Series Reactors
Degradation of steady state voltage
performance
Reactive power support

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


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

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.

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

14
Metering

Import meter needs to be replaced by
import and export meter.

Modes of tie-ups

Banking
Wheeling
Selling

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


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

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.

Electrical Engineering Aspects of Integrating Industries With Captive Generation Sets With The Grid

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