Multiple generators in phase. How?

When I was in the Navy on a submarine we routinely connected each of our two ship’s service turbogenerators (SSTGs) to each other and to shore power.

There was a synchroscope on the electrical panel. You set it up so that you could see the frequency difference between the the two sources being connected.

The synchroscope consisted of a meter with a pointer that rotated in a clockwise or counter-clockwise direction. The clockwise direction was labeled “FAST” and the counterclockwise direction was labeled “SLOW.” The rate of rotation corresponded to how much the two sources differed in their frequencies. The direction of rotation corresponded to which source was higher in frequency.

You were supposed to close the breaker that synchonized the two sources when the meter was going “slowly in the FAST direction.” This meant that the SSTG was slightly higher in frequency than shore power, so it would pick up load and not act as a motor, and the fact that the pointer was moving slowly meant that SSTG was only slightly higher in frequency than shore power.

The breaker needed to be shut when the two sources were exactly in phase. The pointer would be at the 12 o’clock position at this point. In practice, with the pointer moving slowly in a clockwise direction, the breaker was actuated at about the 10 o’clock position so that the breaker actually shut at the 12 o’clock point.

I was an officer, so I only watched all of this. (I did do it myself a few times in training, though.) I had electricians who could switch from one power lineup to another, all manually, in seconds. One guy could synchronize and parallel two power sources before the synchroscope meter even made it once around.

Multi-engine aircraft aren’t much different from submarines in this regard.

Older multi-engine jets, say airliners from the 707 through the early 737 and 747 used a similar system. Each engine drove an AC generator through a hydraulic pump/motor assembly called a “constant speed drive” or CSD. The CSD tried to maintain a constant output (ie generator input) shaft RPM regardless of engine RPM. That way the generator’s frequency would also be constant, at least within the tolerance of the CSD’s governor.

Each generator was connected to a bus which carried some fraction of the total aircraft load. As well, there was a “sync bus” which connected all the generators together. This enabled the entire system to weather a generator dropping off line with no interruptions in supply to anything as long as total load was below the total output capacity of the surviving generators.

It also meant all the generators had to operate on a common frequency and exactly in phase. After each engine was started there was an elaborate ritual the flight engineer (3rd crewman in the cockpit) had to go through to get the newly started engine’s generator synced with the others before connecting it to the sync bus & the loads.

Each unit had a frequency meter and phase difference lights. You’d adjust the free generator’s freq via a knob while monitoring the meter until it matched the indicated freq of the sync bus, then turn on the phase difference lights & fine-tune the free freq until you had a very slow (1 cycle / 10 sec) beat. Fnally, you’d close the switch at the center of the off part of the blink cycle.

Given that CSDs were mechanical beasts whose behavior depended on temperature, difficulties often arose on frigid mornings & sometimes folks had to wait a few extra minutes for the hydraulics to come up to temp before the situation would stabilize enough to connect sucessfully. Many times there was a little breath-holding when the switch was thrown, since you were holding up traffic & the Captain wanted to get under way NOW. This had to be done for each engine start after the first, so a 707 or 747 engineer had 3 chances to screw up on every flight.

There was a mechanical weak link in the generator input shaft and if you really hosed up & tried to connect when grossly out of sync the link would break. This prevented catastrophic generator damage, which was good, but it also meant the flight was cancelled until it could be repaired and you got to go talk to the boss about your ineptitude. And who knew how many times that link had almost been broken from previous ham-handed connects? So most of us treated those links & connect operations with kid gloves.
More modern designs simply keep each generators’ loads isolated in normal ops & if a generator fails an automatic relay will connect the now-unpowered bus to one of the others which still has a generator. As long as the different busses are generally near correct voltage & freq, ie… +/- 10%, it’ll work fine. The loads see a momentary (<1/10th sec) loss of power, but as long as they’re designed for that possiblity, no problem. No more precise syncing is required.

There are also some uber-modern designs that do away with the CSD altogether & produce AC power of widely varying frequency, say 200 Hz at idle & 450 Hz at full power (400 Hz being the historical standard on aircraft). It requires a little different design for some of the loads, but there was never a strong reliance on exact Hz-itude anyhow, so the changes are comparatively minor.

It’s easy to explain with pictures, not so easy to explain in words.

Connect a light between the output of a generator and the “grid” (or another generator). The generator is going to output a voltage sine wave, and the grid is going to have a voltage sine wave. If the two are perfectly in sync, then there won’t be any voltage difference between them at any time during the sine wave, so the light will not light. If they aren’t in sync, then there will be a voltage difference and the light will come on. The farther they are out of sync, the brighter the light will be.

If the generator and the grid aren’t even close in frequency, then the lights will flash so fast as to be meaningless. But, if you get the generator and the grid very close in frequency, the lights will flash much more slowly as the sine waves move close to phase then farther away from being in phase. The closer the generator and grid are in frequency, the slower the lights will flash.

Three phase generators have three such lights, one for each phase. When you watch them, all three lights will get brighter then dimmer then brighter then dimmer. When the lights are at their dimmest (i.e. OFF) the three phases are in sync and it’s safe to throw the switch.

If all three lights don’t get bright and dim at the same time, chances are you have two of the phases reversed, which is a very bad thing. If you like having your generator all in one piece, don’t throw the switch until you get the wiring straightened out.

The National Electric Reliability Council (NERC) has rules for time correction.

They very closely monitor the time in relation to power grid frequency.

They just count the cycles and compare it against NIST time. When the error becomes too great (10 sec) the local coordinating council will notify generating entities to shift the frequency by plus or minus .02 hz at a prescribed time (usually early am).

You can read can read an explanation by one of the coordinating councils on page 26 of this.