Impact of leading power factor

loads on synchronous alternators

by Gary Olson, Cummins Power Generation

Many electrical loads incorporate elements that can impose a leading power factor on the power source. While these loads are typically not
a problem for utility power sources, leading power factor can cause generator set failures or the failure of certain loads to operate properly
on a generator set.

The problems experienced when A utility supply simply absorbs the reactive Paralleling problems
attempting to operate generator sets power output because it is extremely large
Generator sets that are used in isolated
with leading power factor loads may relative to the filter system and it has many bus paralleling systems have particular
seem mysterious, but in reality, they are loads that can consume this energy. With a issues with leading power factor loads.
not too different from another energy generator set, however, the rising voltage When loads are applied to a parallel
absorption problem: the limited ability of from the leading power factor causes generator bus, the total load on the
a generator set to absorb real kW power the voltage regulator to turn down and system can be many times larger than
from loads in certain applications. A reduce alternator field strength. If the the capacity of a single generator set. The
generator is physically unable to absorb AVR turns all the way off it loses control of generator sets close to the bus one at a
more than a very small amount of real system voltage, which can result in sudden time, so that if high loads (either leading
(kW) or reactive (kvar) power. While the large increases in system voltage. The or lagging) are applied before genset
reverse kW power produced by a falling increase in voltage can result in equipment capacity is available, the generator bus
load in a crane application may drive the damage and failure. can fail. With leading power factor loads,
engine into over-speed conditions when the failure mode will be due to either an
it exceeds the ability of the engine to A UPS is designed to recognize high
voltage as an abnormal and undesirable over-voltage condition or reverse kvar
absorb it, the reverse kvar load presented shutdown. Further, there is a tendency,
by leading power factor devices will drive condition, so it can immediately switch
particularly in data centre applications, to
the alternator into over-voltage conditions. off its rectifier. When it does that, the high
group UPS loads together on a common
voltage condition is immediately relieved
O v e r t h e p a s t y e a r s, g e n e r a t o r s e t bus. This concentrates the leading power
(because the filter is disconnected from
manufacturers have evolved their factor load on one bus, so that if a large
the generator set) and voltage returns to
equipment designs to include the use UPS load is applied to the first generator
normal. To the observer, the generator will
of digital automatic voltage regulators set available, it can easily be driven into
seem to be unable to pick up the system
(AVR), separate excitation systems, and an excess reverse var condition, which
load.
PWM-type control architecture to enable
the generator set to produce a stable
output voltage and successfully operate
non-linear loads. At the same time,
manufacturers of equipment that has
non-linear load characteristics have
begun to commonly employ filters to limit
harmonic current distortion induced on
the power supply. Capacitive elements
are also applied in facilities to improve the
power factor when operating on the utility
source to avoid higher energy charges.
While filters provide positive impacts on
the overall power system, they can be very
disruptive to generator operation.
The AVR monitors generator output voltage
and controls alternator field strength
to maintain constant output voltage.
Relatively low AVR output is required to
maintain generator voltage at no load.
In Fig. 1, the no load exciter field current
required is less than half the full load level.
Filter equipment is often sized for operation
at the expected maximum load on the
UPS or motor load. At light loads there may
be excess filter capacitance, causing a
leading power factor. Since rectifiers are
commonly designed to ramp up from zero
load to minimize load transients, leading
power factor loads may be imposed on
the system until inductive loads are added
to the system or the load factor of the non-
linear load increases. Fig. 1: In this example no load field required is 17 A, while full load is approximately 38 A.

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GENERATION
 loads may be required to be broken into
smaller blocks of UPS and mechanical
loads, rather than larger isolated buses
of each.
The filters should be turned off when
operating on the generator set or reduce
the magnitude of filtering provided. If
the generator is provided with modern
digital excitation control, the filters won’t
be needed to maintain stable generator
operation, but may still be required to
properly serve other loads.

The actual limits of reverse kvar can vary

considerably from machine to machine,
both within a specific manufacturer ’s
product line, and between equipment
from different suppliers. A good rule of
thumb for certain equipment is that it can
Fig. 2: Green area is normal operating range of a typical synchronous machine, yellow is
abnormal but not damaging, and operating in red regional will cause damage or failure. absorb about 20% of its rated kvar output
in reverse kvar without losing control of
voltage.
will result in over-voltage and shutdown. If necessarily the generator set, which may
multiple generator sets are on the bus and have a lower rating). Alternators are physically limited in their
a large reverse var load is applied to the ability to both produce and absorb power.
The normal operating range of a generator
genset bus, the var load sharing control When a leading power factor load is
set is between zero and 100% of the kW
system can be disrupted, because not all applied to an alternator at a site, generator
rating of the alternator (positive) and
load sharing control systems include logic failure, over-voltage, load failure, and
between 0,8 and 1,0 power factor (green
for reverse kvar load sharing. If reverse kvar alternator damage can occur. There is
area on curve). The black lines on the
load sharing is not in the control system’s very little that the alternator supplier can
curves show the operating range of a
logic the system will typically cause one do to resolve problems at a specific site
specific alternator when operating outside
or more generator set to exceed their other than to help a system designer
of normal range. Notice that as power
reverse power limits, which can cause understand the nature of the problem and
factor drops, the machine must be de-
pole slipping. the limits of the machine as installed. Most
rated to prevent overheating. On the left
Generator sets in a paralleling system quadrant, the near-normal output (yellow of the solution will come from changes
are maintained in synchronism by their area) can be achieved with some leading in the system sequence of operation, or
magnetic fields. When a leading power power factor load, in this case, down hardware changes that prevent disruptive
factor load is applied, the voltage of to about 0,97 power factor, leading. At reverse var conditions from affecting the
the genset or bus rises, and the voltage that point, the ability to absorb additional generator set.
regulation system of each generator kvar quickly drops to near zero (red area),
Conclusions and recommendations
set reduces exciter power, reducing indicating that the AVR is “turning off ” and
the strength of the magnetic field. If any level of reverse kvar greater than the  Synchronous alternators have limited
the field is switched off in an attempt level shown will cause the machine to lose ability to absorb kvar from load
to reduce voltage to an acceptable control of voltage. devices, and exceeding this limit will
level, the generator set may slip a pole, result in generator set shutdown.
In other words, if the machine is rated
which results in potentially catastrophic Paralleling operations require careful
for operation at 1000 kVA and 0,8 power 
alternator damage. The reverse kvar limit consideration of the loading sequence
factor (600 kvar), with a reverse kvar level
of the aggregated generators is the sum to prevent reverse var conditions that
of 0,2 per unit, the machine’s capabilities
of the reverse var limits of each generator. can damage the generator set.
will be exceeded. So, with more than
However, the reverse var settings may
120 kvar reverse power and leading power  Consider modifying system sequence
not be able to take advantage of all
factor lower than 0,97 (for most people a of operation or limiting filter operation
the capability of the alternators due to
surprisingly low level) we have a problem. until adequate loads are in place to
limitations in the var load sharing system.
The solution to this problem on this specific prevent reverse kvar conditions on the
Solutions machine involves avoiding excess reverse genset.
kvar levels through proper system design
What can be done about this? First, we  Specify the magnitude of reverse kvar
and operation.
need to understand how much reactive the genset must be able to absorb, not
power can be absorbed by the generator The sequence of operation must be the power factor alone.
without negative impact. The ability of an modified so that loads that require reactive  In single generator applications
alternator to absorb power is described power are present on the bus when protective devices can be set to the
by a reactive capability cur ve. Fig. 2 the UPS connects to the generator. The
shows a typical generator capability curve limits of the alternator.
reactive power produced by the filters will
describing the capability of a machine  In paralleling applications both
be consumed by the system loads, and
to produce and absorb power. In this alternator limits and var load share
the loss of voltage control is avoided.
curve the kvar produced or absorbed is limits must be considered.
This requires a re-thinking of operating
on the x-axis (positive to the right). The
y-axis shows kW (positive going up). kvar sequences in some cases because: Contact Dave Wardell,
and kW are shown as per unit quantities  Mechanical loads rather than UPS may Cummins, Tel 011 589-8428,
based on the rating of the alternator (not need to go on the generator first. [email protected] 

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