POWER SYSTEMS TOPICS 110

Power Up With a Load-Management System:

IDENTIFYING LOAD-MANAGEMENT
SYSTEM APPLICATIONS
AUTHOR INTRODUCTION
ISAAC FRAMPTON
Senior Staff Engineer
Load-management systems can improve flexibility, versatility and power
Kohler Co. quality of a power generation system. This three-part series explores tips
Power Systems Division
for setting up load-management systems along with guidelines for seven
Part 1 of a 3-part series load-management methods. This first installment focuses on appropriate
applications of load-management systems where controlling load priorities
can improve power quality to critical loads.

WHAT IS LOAD MANAGEMENT

A load-management system allows conditions such as generator load, output
industrial management and facilities voltage or AC frequency. On a multi-
engineers to control when a load is added generator system, if one generator shuts
or shed from a power system, making down or is unavailable, load-management
paralleling systems more robust and enables lower priority loads to be
improving power quality to critical loads on disconnected from the bus. This ensures
many power generation systems. that the critical loads are still operational
In the simplest form, load management, even with a system that has an overall
also called load add/shed or load control, capacity lower than originally planned.
allows removal of noncritical loads when In addition, by controlling how many and
the capacity of the power supply is which noncritical loads are shed, load
reduced or unable to support the entire management can enable a maximum
load. If the noncritical loads are removed, number of noncritical loads to be
critical loads can retain power under supplied with power based on the actual
circumstances where they could otherwise system capacity.
experience poor power quality due to an In many systems, load management can
overload condition or lose power due to a also improve power quality. For example,
protective shutdown of the power source. in systems with large motors, the starting
It allows for removal of noncritical loads of the motors can be staggered to allow
from the power generation system based a stable system as each motor starts.
on certain conditions such as a generator Load management can further be utilized
overload scenario. Load management to control a load bank so when loads are
enables loads to be prioritized and below a desired limit, the load bank can
removed or added, based on certain be activated, ensuring proper operation
of the generator.
 Load management may also provide load relief Although most generators are typically
so that a single generator can connect to the bus synchronized and connected to the paralleling
without being overloaded immediately. Loads can bus within a few seconds of the first
be added gradually, with a time delay between generator closing, it is not uncommon for the
adding each load priority, enabling the generator to synchronization process to take up to a minute,
recover voltage and frequency between steps. long enough for an overload to cause the
generator to shut down to protect itself.
Other generators can close to the dead bus
WHEN TO USE LOAD MANAGEMENT after that generator shuts down, but they will
There are many instances where load have the same load that caused the other
management can improve the reliability of a generator to be overloaded, so they are likely
power generation system. A few applications to behave similarly (unless the generators are
where the use of load management may be different sizes).
implemented are highlighted below. In addition, it can be difficult for generators
• Standard paralleling systems to synchronize to an overloaded bus due to
abnormal voltage and frequency levels or
• Dead-field paralleling system frequency and voltage fluctuations, so the
incorporation of load-management can help
• Single-generator systems bring additional generators online more quickly.
A properly configured load management system
• Systems with special emissions requirements will typically provide good power quality to
critical loads during the synchronization
process by ensuring that the online generators
STANDARD PARALLELING SYSTEMS
are not overloaded, even if the synchronizing
Most standard paralleling systems have use for process takes longer than expected.
some type of load management because the
Load management may be implemented in a
load must be energized by a single generator
multitude of ways. Standard paralleling systems
before the others can synchronize to it and add
are often controlled by paralleling switchgear as
power generation capacity. Further, that single
shown in Figure 1. The paralleling switchgear
generator may not be able to supply the power
typically contains a programmable logic control
requirements of the entire load.
(PLC) or other logic device that controls the
Standard paralleling systems will start all sequence of operation of the system. The logic
generators simultaneously, but they are unable device in the paralleling switchgear can also
to synchronize to each other without one perform the load management.
of them energizing the paralleling bus. One
generator is chosen to energize the bus so that
theWith
Parallel Generators others
Loadcan synchronize to it.
Parallel Generators With Load
ors With Load Management in Controller
Parallel Generators With Load
Management in Switchgear

in Controller Management in Switchgear C

M M

M M
Key:
Motor-
C M Operated
Unimportant Load
Critical Load

Important Load

M Gen Gen Breaker

Unimportant Load
Critical Load

Important Load

C C
M M
Gen Gen Gen
Key:
Generator

Motor-
Operated
MController
Unimportant Load
Critical Load

Important Load

Parallel Generators with Parallel Generators with Building Breaker

Unimportant Load
Critical Load

Important Load

Load Management System (LMS) Management System (BMS) Paralleling

Switchgear

C Gen
LMS Gen Gen
Control
Generator
M M M M
Figure 1: Parallel Generators with
Load Management in Switchgear
C Controller
Unimportant Load

Unimportant Load
Critical Load

Critical Load
Important Load

Important Load

nerators with Parallel

2 / Load Management Systems PartGenerators
1 with Building
Gen Gen Gen Gen
BMS

ent System (LMS) Management System (BMS) Paralleling

Switchgear
 Critic

Unimporta
Importa

Unimportant Lo
Critical Lo

Important Lo
C C
Gen Gen

POWER SYSTEMS TOPICS 110

Parallel Generators with Building

Management System (BMS)
DEAD-FIELD PARALLELING SYSTEMS
LMS
C Dead-field paralleling differs from standard
paralleling in that all generators can be
M M paralleled before their
M voltage regulators
M are
activated and the alternator fields are excited.
If all generators in a dead-field paralleling
system start normally, the power system

Unimportant Load

Unimportant Load
Critical Load

Critical Load
Important Load

Important Load
reaches rated voltage and frequency with full-
power generation capacity available to supply
Gen Generators
Gen With Load the load. Gen Gen
s With Load Parallel
Controller Management in Switchgear Because the normal dead-field paralleling
Figure 2: Parallel Generators with
sequence does not require a single generator
Load-Management System C (LMS) to energize the paralleling bus, load
management should not need to shed load
Load management
M may
M be performed by a
Key:
during a normal system start. However, as with
separate load-management system (Figure 2), standard paralleling systems, the starting and
Motor-
which may provide metering or may use stopping
M
of individual generators is possible
Operated
Unimportant Load
Critical Load

Important Load

information from the paralleling switchgear with dead-field

Breaker paralleling. If a generator is
Unimportant Load
Critical Load

Important Load

controls to determine generator loading down for service or stops for another reason,
and frequency. the other generators may still be overloaded.
Gen Gen Gen Generator
Thus, load management may still be useful
A building-management system may also in these applications,
perform load management, controlling the Parallel Generatorssimilar
With to standard
Load Parallel
paralleling systems.
loads by supervisory control and eliminating Management
C Controller in Controller Manag
rators with the need for
Parallel switches to interrupt
Generators the power
with Building
to them Figure 3. Paralleling
t System (LMS) Management System (BMS)
Switchgear
M M

LMS M
C
Control Unimportant Load
Critical Load

Important Load

M M Gen Gen

C C
Gen
Unimportant Load

Unimportant Load
Critical Load

Critical Load
Important Load

Important Load

Figure 4: Parallel Generators with

BMS Load Management in Controller
Gen Gen

Parallel
Dead-field Generators
paralleling with
is usually performed by Parallel
Load Management
parallel-capable System
generator (LMS)as shown
controllers Mana
Figure 3: Parallel Generators with in illustration 4, but it can also be performed
Building Management System (BMS)
by a paralleling switchgear
C
installation.
LMS

Parallel-capable generator controllers often

provideMbuilt-in loadM management, allowing M
the load priorities to be directly managed by
the controllers and eliminating the need for
paralleling switchgear controllers.
Unimportant Load
Critical Load

Important Load

Gen Gen Gen

Load Management Systems Part 1 / 3

SINGLE-GENERATOR SYSTEMS SYSTEMS WITH SPECIAL
EMISSIONS REQUIREMENTS
Single-generator systems are typically less
complicated than their paralleling counterparts. In some geographic areas, there are minimum
Such systems may use load management load requirements for a generator anytime it is
in the generator controller to control loads operating. In this case, load management could
when subject to intermittent loads or load be used to keep loads on the generator to help
variations. Figure 5 shows a single generator meet emissions requirements.
system using automatic transfer switches to
Single Generator
interrupt loads.
For this application, the power generation
system is fitted with a controllable load bank.
controlling ATS The load-management system is configured
Key:
to energize various loads in the load bank to
Single Generator with Special
maintain the generator system output power
Gen Generator
Gen Emissions Requirements
above a threshold Figure 6.

C
C Controller
Unimportant Load
Critical Load

Important Load

Utility Ge
Automatic
Gen

Load
Transfer
Switch
C
Figure 5: Single-Generator Controlling ATS
Load Bank
C

An intermittent load—such as chillers, induction Figure 6: Single Generator with

ovens and elevators—does not draw continuous Special Emission Requirements
power, but it can vary power requirements
Certain generator systems include a Diesel
suddenly and significantly. Load management
Particulate Filter (DPF), which typically needs to
can be useful in situations where the generator
be regenerated. In some cases, engines will
is capable of handling a normal load, but
derate to 50 percent of rated power during a
under certain circumstances intermittent
parked regeneration of the DPF, and could
loads may increase the total load of the
leverage the load-management system to
system above the maximum power capability
remove some loads during that condition.
of the generator, potentially hurting the power
quality of the generator output or inducing a
protective shutdown.

Load management can also be used to stagger

application of loads to the generator, minimizing
the voltage and frequency variation caused
by the inrush to large motor loads. Load
management may also be useful if local codes
require a load control module for systems where
the rated generator output current is less than
the service entrance current rating.

Load Management Systems Part 1 / 3

 POWER SYSTEMS TOPICS 110

WHEN LOAD MANAGEMENT

MAY NOT BE NECESSARY
Although load management can improve PARALLELING GENERATORS
power quality to critical loads in any system, FOR REDUNDANCY
it may add delays before some loads receive Load management is generally unnecessary
power, increase the complexity of the in situations where there are paralleling
installation and add a significant amount generators and the site power requirements
of wiring effort as well as parts cost, such can be supported by any one of the generators,
as contactors or circuit breakers. Some as a generator failure will only result in another
applications where load management may generator starting, with only a temporary
be unnecessary are outlined below. interruption in the load.
ALL LOADS ARE EQUALLY CRITICAL
PROPERLY SIZED SINGLE GENERATOR On sites where all loads are equally critical,
There is usually no need for a load-management it is difficult to prioritize the loads, shedding
system on a properly sized single generator, as some critical loads in order to continue
an overload condition is unlikely, and generator providing power to other critical loads. In this
shutdown will result in all loads losing power, application, the generator (or each generator
regardless of priority. in a redundant system) should be appropriately
sized to support the entire critical load.
The next installment of this three-part series will
explore setting up load-management systems,
determining load priority orders and methods
of shedding loads.

4 / Load Management Systems Part 1

 POWER SYSTEMS TOPICS 110

ABOUT THE AUTHOR

Isaac Frampton is a Senior Staff Engineer at Kohler Co. He has

worked for the company’s Kohler Power Systems division since 2006
and specializes in control system design and paralleling applications.
He has a bachelor of science in electrical engineering from Kettering
University in Flint, Michigan.

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