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Design considerations for

generator set mounted
paralleling breakers
White Paper
Hassan Obeid, Application Group
Cummins Power Generation

Cummins Power Systems has been Paralleling of generator sets is enabled by using
delivering simple paralleling electrically operated circuit breakers which are
typically mounted in switchgear. Switchgear is
solutions since the introduction of
defined as a metal-enclosed structure which
PowerCommand digital paralleling
®

contains bus bars, insulating material, connecting

in the early 1990s. The typical means, either stationary or drawout, manually or
paralleling system included electrically operated circuit breakers in individual
metal compartments, Exhibit-01. The switchgear
generator set paralleling breakers
may also contain controls, instruments, metering
commonly located in a switchgear and protective equipment. Traditionally, the
lineup remote from the generator switchgear also included all discrete components
sets. Some markets are now driving needed for paralleling generator sets. Components
such as speed governors, voltage regulators,
for an option to mount the generator
reactive and real power load share controls, fuel
set paralleling breaker on the ramping controls and protection for reverse power
generator set itself. There are (anti-motoring) and loss of field (under excitation).
challenges associated with this type
To improve the overall power system reliability,
of design. The objective of this paper some OEMs such as Cummins design their
is to outline and address these paralleling scheme using what is called distributed
challenges in an effort to provide an logic architecture. Cummins accomplishes this
understanding of how to apply the type of architecture with PowerCommand Control,
which is an autonomous microprocessor-based
advantages of this design and still
control for protection and paralleling functions.
maintain design integrity and system Therefore, the paralleling scheme is redundant on
reliability. every generator set. In certain applications, the
paralleling breaker can be mounted on the
generator set, Exhibit-02, thereby eliminating the
need for the switchgear described above. The
physical paralleling point in this situation can be
either a collector bus or a switchboard, Exhibit-03.
 Generator Sets Grid

Generator Sets Grid

Distribution
Boards

Distribution
Exhibit-01: Paralleling Boards Switch
Transfer
switchgear
Transfer Switch

Loads

Loads

Exhibit-04: Typical isolated-

Loads
Exhibit-02: Generator set mounted paralleling breaker bus configuration Loads

Generator Set Grid

Grid
Generator Set

Collector Bus
Collector Bus

Load Exhibit-05: Typical infinite

bus transfer-pair system
Load
configuration

Exhibit-03: Collector bus

The point of common connection of paralleled genera- Design considerations for

tor sets with set-mounted paralleling breakers is either
at a distribution board or a collector bus, as opposed a generator set mounted
to traditional paralleling, where it takes place in the paralleling breaker
paralleling switchgear. Exhibit-04 shows a systems
configuration with generator set-mounted paralleling In paralleling applications, the system requirements,
breakers. In this example, two generator sets with overall physical layout, size and one-line configura-
set mounted paralleling breakers are connected to a tion all influence the switchgear design. Also, there
distribution board feeding downstream loads through are rules and guidelines which are outlined in the
two transfer switches. Exhibit-05 shows a transfer- NEC, UL and NFPA that need to be considered,
pair application with single generator set/single utility as well as the Authority Having Jurisdiction (AHJ),
connected to a collector bus feeding downstream when designing a paralleling system and in particu-
loads. The Cummins PowerCommand Control has the lar as it relates to the common point of connection
capability to control the utility main breaker and also of the paralleled sources. The following are some
has built-in protection to isolate the generator set in the design considerations associated with paralleling
event of a fault. and the common point of connection:
02
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1.\ Maximum Available Fault Current – The point of Where:
common connection must withstand the physical kW: kilowatt output rating of the generator set
and thermal stresses caused by fault currents
from all sources. The power cables between the p.f.: generator set rated power factor
generator sets and the point of common connec- V: generator set rated output voltage
tion must be braced to handle fault currents.
X"d: alternator per unit subtransient reactance based
2.\ Load Flow Analysis – The ampacity of the point on the generator set rating
of common connection must handle the current Imlfc = Motor Load Fault Current ≈ Locked
contribution from all generator sets. Rotor Starting Current

3.\ Ground Fault – Isolate and properly detect a Iutfc = Utility Fault Current ≈ transformer steady state
ground fault without causing nuisance tripping; rating divided by the transformer impedance
the neutral and ground are bonded in one place
The maximum available fault current, Imafc, must be
in four-wire systems.
less than or equal to the equipment bracing level
4.\ Generator Set Isolation – Concurrently maintain design. In the event of a fault, the power cables
generator sets and isolate faults. must withstand the fault current thermal effects
and might move or jump due to the high levels of
magnetic forces. Therefore, the system design
1. Maximum available fault current:
engineer should take into account the physical
An essential factor in paralleling system design is
bracing of the power cables and apply appropriate
the maximum available fault current (Imafc), peak and
strain reliefs. Also, the capacity and temp rise of
RMS. Imafc is the sum of the available fault current
the power cable are of high importance for the
from all generator sets (Iafc), motor loads (Imlfc) and
same reasons. And the impedance of the cables
utility distribution transformers (Iutfc) that can be
should also be considered in the full evaluation of
simultaneously connected to the system. The value
the system. For example, if there are multiple power
of Imafc is used to determine the physical construction
sources connected together and a fault takes place,
and mechanical bracing required to safely sustain
the lugs and power cables must be able to withstand
a fault at that level without danger of mechanical or
all the available fault current. See Exhibit-06, which
electrical failure.
shows a fault in the power cables between generator
When a short circuit occurs in a power distribution set 1 and the distribution board. The cable and
system, very high levels of current will be drawn lugs at point ‘A’ must withstand the fault current
to the fault. These high magnitude currents rise contributions from the two motors and generator sets
quickly and develop strong magnetic fields which 2 and 3. The paralleling circuit breaker must have
tend to force apart bus bars and power cables. If the proper interrupt rating to open the circuit under a
the electrical distribution equipment is not properly fault without being damaged or causing an arc flash.
designed and installed, the bus structure or other
power conductors can mechanically fail, causing a
Generator Sets
catastrophic failure of the power system.

It is critical that the system designer verifies the level

of available fault current in the system, and specifies
equipment that will be suitable for the application.
All of the supply side (utility or generator set) circuit Iafc1 Iafc2 Iafc3
breakers in the paralleling system require an interrupt
rating that is ≥ Imafc. Fault
A
Imafc = Maximum Available Fault Current = Iafc1 +
Iafc2 +... + Imlfc1 + Imlfc2 +... + Iutfc1 + Iutfc2 +...

Iafc = Generator Set Available Fault Current = Imlfc1 Imlfc2

(kW*1,000)/( √3*V*p.f.*X"d)

Distribution Board
Exhibit-06: System fault
03
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 2. Load flow analysis: Generator Sets

The system design engineer needs to perform a sys-

tem load flow analysis, which can be done by knowing
the generator set size and quantity, calculating the
generator supply current (Igsc), and total supply current
(Itgsc). Also, the maximum available fault current as Igsc1 Igsc2 Igsc3 Exhibit-09: Using a
described in the previous section should be taken into 6,000-amp bus
2,000A 2,000A 2,000A
consideration. Igsc is used to determine the paralleling
circuit breaker frame size and trip level. Improper de- 6,000A Bus
sign can jeopardize the system reliability and integrity.
Igsc = Generator Supply Current = kW/( √3*V*p.f.) 2,000A/Feeder

Itgsc = Total Generator Supply Current = Igsc1 + Igsc2 +

Distribution Board
Igsc3 + .......+ Igscn
Exhibit-09. Using a 6000 amp bus
If the total supply current of the generators is greater 3. Grounding:
than the paralleling bus ampacity, then the loads
For optimum continuity of power for critical loads
can be spread out along the paralleling distribution
and for the safety of personnel, careful consideration
panel to overcome this issue. The current flow at any
of the grounding arrangements of generator sets
point on the bus cannot exceed the continuous rating
used in emergency and standby power systems is
of the system main bus selected. Exhibit-07 shows
essential. Specific considerations for emergency
that the capacity of the bus is exceeded at point ‘A’,
and standby systems include selection of a system
since the contribution from all three generator sets
grounding method for the generators, requirements
is 6,000 amps. By applying load flow analysis and
for indication only of a ground fault on the generator,
reconfiguring the bus, Exhibit-08, the continuous
and the methods used in transfer equipment for
rating of the bus is no longer exceeded. Another way
switching the neutral pole.
to overcome this challenge is to use a 6,000-amp
distribution board or collector bus, Exhibit-09. The National Electric Code (NEC) 2014-230.95
requires Ground Fault Protection (GFP) at the service
disconnect (utility breaker) for systems with: solidly
Generator Sets grounded wye, more than 150 volts
Generator Setsto ground
(277/480 or 347/600VAC) and over current device
rating of 1,000A or more. Ground Fault Indication
(GFI), not protection, is required at the emergency
source (NEC 700.6 (D).
Igsc1 Igsc2 Igsc3 Exhibit-07: Exceeding Igsc1 Igsc2 Igsc3
bus capacity
2,000A 2,000A 2,000A Generator
2,000A Sets2,000A 2,000A
A
4,000A Bus 4,000A Bus

Overload 2,000A/Feeder 2,000A 2,000A 2,000A

Distribution Board Distribution Board

Exhibit-07. Exceeding busGenerator

capacity Sets
Exhibit-08. Re-configuring the bus

Generator Sets
Neutral

Igsc1 Igsc2 Igsc3 GFR

Exhibit-08:
Re-configuring the bus 2,000A 2,000A 2,000A
GFR: Ground Fault Relay
Igsc1 Igsc2 Igsc3
4,000A Bus
Exhibit-10: Four-wire system
2,000A 2,000A 2,000A
Exhibit-10. 4-wire system
er 2,000A 2,000A 2,000A
04

6,000A Bus
Distribution Board
■■

2,000A/Feeder
city Exhibit-08. Re-configuring the bus
Distribution Board
Adequate equipment and system grounding are Furthermore, isolation at the point of common
necessary for creating an effective path for ground connection improves reliability by preventing that
fault current to return to the source. One of the aspects connection from being a single point of failure. Without
for properly detecting ground fault current is to isolation, the occurrence of a cable fault between any
appropriately select and place current transformers generator set and the point of common connection
(CTs) in a power system. Detecting ground current can will result in all generator sets disconnecting and
be done using the residual method, zero-sequence shutting down. Isolation for each unit at the point of
or source ground return method. The source ground common connection will isolate the fault from the other
return method is typically what is used in paralleled generator sets and allow them to continue to supply
systems where CTs must be placed on the neutral power to the loads.
to ground bond. In four-wire systems, the bonding
Generator Sets
takes place in the distribution panel/collector bus,
Exhibit-10. In three-wire systems, the neutrals can be
bonded at the generator sets, given the generator
sets are identical. Neutrals of dissimilar generator sets
should not be interconnected to prevent circulating
currents. The system designer needs to be aware of
the space constraints when the paralleling gear is
a riser collection bus or a small switchboard and all
of CT wires need to be possibly brought back to the
paralleling breaker trip units.

Ground fault schemes require further evaluation when

interfacing a generator set mounted circuit breaker with
another switchboard that includes generator set(s), a
utility, or other alternative energy source connection.

4. Generator set isolation: Distribution Board

Exhibit-11: Fused disconnects
Considerations should be given to generator set Exhibit-11. Fused disconnects
isolation for maintenance. To perform maintenance
Additional methods for point of common
on a generator set, there must be means to individually
disconnect each generator from the paralleling
connection
distribution bus. This can be accomplished at the Utilizing the lugs on an ATS as a paralleling point,
paralleling switchboard by using fused disconnects. It Exhibit-12, or daisy-chain the power cables from one
can also be accomplished by using the generator set generator set to another and then go to a collector
mounted paralleling breaker. However, if there are no bus or switchboard. Exhibit-13 some additional
disconnects at the distribution board, the load side of options. However, achieving generator set isolation
the breaker will be energized if other generator sets with these methods as shown in Exhibits-12 and 13,
are online. In this case, performing maintenance on an will be challenging. Other design considerations
individual generator set requires taking all sets offline. noted above, e.g., load flow analysis, maximum
This reduces reliability because the system is no longer available fault current and physical bracing will
concurrently maintainable. Refer to Exhibit-11. need to be addressed as well.

Another important factor to note is when a downstream

disconnect switch is used, without proper design and
protection there is a high risk factor of closing out of
phase if an operator opens the disconnect switch and
then closes it again while the bus is energized while the
generator set is running; see Exhibit-11. An interlocking
scheme between the paralleling breaker and its
respective disconnect switch can be employed, which Exhibit-12: Transfer switch
may prevent this type of occurrence. as a paralleling point
05

Transfer Switch
■■

Exhibit-14. Transfer switch as a paralleling point Exhib

 Conclusion
Paralleling with generator set mounted paralleling
breakers can be used in a variety of applications
such as oil and gas, mining, commercial and
municipal buildings, and healthcare clinics. This
type of paralleling equipment may offer multiple
attractive advantages, such as cost-reduction,
smaller footprint, and ease of wiring and
integration. However, the apparent advantages
Exhibit-13: Daisy-
should be viewed alongside the design
chaining power cables
challenges and carefully considered to ensure
maximum system reliability and adequate design.

Loads
point Exhibit-15. Daisy-chaining power cables

About the author

Hassan Obeid is a technical specialist in the power seminars on several topics and products.
Application Group at Cummins Power Generation. Hassan led the switchgear design for the BEAR
He has been with Cummins since 2007 in a variety 800 kW Mobile Power Unit for the Air Force.
of engineering roles. Hassan has designed power He received his bachelor’s degree in computer
systems involving switchgear controls, transfer science and master’s degree in electrical
switches, generator sets and remote monitoring. engineering from Minnesota State University,
He has developed and conducted technical Mankato.

Cummins Power Generation

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Shoreview, MN 55126
U.S.A.

Phone 763-574-5000
USA toll-free 877-769-7669
Fax 763-574-5298

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