Transcript Slide 1

Genset Sizing with SpecSizer
Steven Baker
EP Commercial Marketing
June 2012
SpecSizer Value
• Accurately sized gen-sets
– Perform efficiently
– Meet site operating demands
Least Cost
Installation
• Improperly sized gen-sets
– Adds cost
– Poor performance
– Undersize
• Additional gen-sets to meet job site
requirements
• Job site footprint designed around
smaller genset
– Oversize
• Competitive bid/price disadvantage
• Engines operate continuously at light
load; prone to wet stacking, slobber
(cylinder bore and liner glazing)
June 2012
Under-sizing
Over-sizing
SpecSizer Performance to Standards
•
Specifying generator sets for
voltage and frequency transient
response
– NFPA 110
• North American spec
• Generator must start, pick up fullrated load, maintain stable
voltage and frequency
– ISO8528-5
• world-wide standard
• defines operating limit values for
performance classes G2-G4, for
critical genset sizing parameters
• transient frequency deviation
(dip), transient voltage (dip), and
frequency and voltage recovery
time
June 2012
SpecSizer Performance Capability
•
Project Parameters:
Conventional vs. Frequency
Limited Sizing
Alternator Engine
Influencing Parameters
Genset Transient Response
SpecSizer Help
June 2012
speed rpm / frequency (50Hz / 60Hz)
radiator size, fan speed
Secondary:
13 Engine Governor Design
•
turbo, fuel injector
Site
•
Primary:
1 Engine Design & Displacement
2 Engine Power Density (BMEP at price list rating)
3 Fuel (liquid vs. gas)
4 Alternator Design & D²L (e.g. Kgmotor & Kgblock)
5 Voltage Regulator
6 a Slope / Gain
7 b Knee frequency
8 c PID leads / lags
9 Load Scenario
10 a Type & size of loads
11 b Power Factor (e.g. lights vs. motor)
12 Site Ambient conditions & Cooling Capacity
14 GenSet Inertia (Engine & Alternator)
aftercooler, compression ratio with AB-C series engine redesign, enclosure
alternator voltage adjustment (dial
down e.g. 480V to 416V)
Getting Started
• Select
– New 3-Phase or Single Phase Project
– Open Existing Project
– Use Wizard
Tip: Easier to use the
Wizard icon for Wizard.
Wizard Icon
June 2012
Set Your Preferences
• Menu bar
– File, Preferences
– (8) Languages
June 2012
Help is Available
• Help (Project Parameters)
– Generator Set Duty
– Sizing Methodology
– Emissions Certification
June 2012
• Menu bar
– Help Topics
Links for Sales Support
• Menu bar
– Cat.com
– Spec Sheets
• Cat.com
– http://www.cat.com/cda/layout?m=37480&x=7
• Dealer locator
– http://www.cat.com/powergeneration/specsizer
June 2012
Project Parameters Features
• Standby Caterpillar & Olympian
– Caterpillar 300 – 3100 kVA
• C175-20 (5000 kVA)
– Olympian 13.8 – 700 kVA
• Best Fit Transient Performance
– CDVR @ Std vs. Optimized VR Slope
• Percent of Intermittent Motors
– diversity factor for competitive sizing
June 2012
Load Scenario
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Linear & Non-Linear Loads
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3-phase Motor (w/ VFD/VSD, Soft Starter)
Single phase Motor
3-Phase Air Conditioning (w/ VFD/VSD, Soft Starter)
Single Phase Air Conditioning
Centrifugal Pump (w/ VFD/VSD, Soft Starter)
Lighting
Range < 40%
• Fluorescent, Incandescent, Gas Discharge, Ultraviolet
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June 2012
Resistive
Office Equipment
UPS
Battery Charger
Medical
Elevator
Induction Furnace (w/ Thyristor)
Welder
Miscellaneous (w/ Pulse Rectifier)
Non-Linear Loads
Generator Set Selection
• Sizes & Selects Genset
• Load Analysis Summary
– Algorithms
– Site Conditions + Load Scenario
– Inrush, Running & Non-Linear
kW & kVA
• Load dialog inputs
• Load sequencing
• % Genset Rated Capacity (EkW)
June 2012
Generator Set Selection
• Starting & Selection Analysis
– Genset list per
• Region installed (price list)
• Site Conditions (e.g. Standby)
– Selection per
• Load characteristics
(e.g. linear vs. nonlinear)
• Site Conditions
(e.g. Altitude & Ambient)
– Derate
June 2012
Generator Set Selection
• Starting & Selection Analysis
– Genset Transient Capability
• Factory genset transient
performance tests
• Volts/Hz Optimization
C175 3000 kVA vs. 3516B 2500kVA
June 2012
Generator Set Selection
• Go to Best Fit Genset
• Guide Spec
– MS Word doc, editable
• Paralleling
• Customer/Dealer Sales
Support Links
June 2012
Generator Set Selection
Load requirement
• Note
provided:
Why the next
smallest
genset fails
Loads require 1613.9
RkW
2500kVA Genset
capable of 1497.8
RkW when derated
June 2012
Generator Set Selection
• Alternator Frame Options
Alternative Genset (with capable alternator) to sized genset in Inventory?
Table provides Cat dealer options.
June 2012
Technical Tab
•
Sizing Report
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Load Analysis Summary
Generator Set
Engine Technical Data
Alternator Technical Data
Load Report
– Permitted Dip
– Predicted Dip
– Load Analysis
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Maximum Step and Maximum Peak SkVA/SkW
Final Running kVA/kW
Step transient performance graph
Transient Performance Report
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June 2012
Step Fdip and Vdip
Step Transient Performance Graph
Block Load Transient Performance Table
Block Load Transient Performance Graph
SpecSizer - Load Transients & Genset Transients
Load Transients
Genset Transients
June 2012
Sizing Competitive Gensets
• Accurate Sizing
– Continuous development since 1/2006
– NPI updates 2x-3x annual
– Pre-release regression testing
• Competitive Sizing
– Benchmark against competitor tools
– Robust algorithms
– Factory gen-set transient response test
data
June 2012
Competitive Sizing Options
• Restrictive Fdip / Vdip
• Wizard
– 20 Steps, Optimum step
• Motor Starting
– Reduced Voltage Starters
• Motor Starting, Low Inertia Motors
• Non-linear loads, Filters & Pulse
Rectifiers
• Efficiency, Air Conditioners
– EER & SEER
• Voltage Regulator Optimization
• @Site Voltage (Amps)
• Load Factor (Duty Point)
June 2012
Restrictive Fdip / Vdip
•
Loads & Steps with restrictive frequency dip
(Fdip) and voltage dip (Vdip)
– cause all loads or load steps sequenced later
in a Load Scenario to adopt the same
restrictive frequency or voltage dip
– (e.g. 30%) Fdip / Vdip loads adopt 10% Fdip /
Vdip if the prior step contained restrictive dip
– Avoids over-sizing the gen-set
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If possible - sequence restrictive loads later in
load scenario
– e.g. UPS load
– Must adhere to specification
June 2012
Restrictive Fdip / Vdip
Resized: 2500kVA 3516  1750kVA 3512B
June 2012
Step#1 Motor load with 10% Fdip
moved to Step#2
Restrictive Fdip / Vdip
1750kVA 3512B
June 2012
20 Step Wizard & Optimum Step
4 Steps  15 Steps
3512 (1137kVA)  C18 (545 kVA)
June 2012
Reduced Voltage Starters
SpecSizer’s 3-phase Motor Reduced Voltage Options &
Respective Torque Limitations
Reduced Voltage
Starter
• Cost-benefit analysis
80% tap
64%
• Cost of Starter
vs.
• Cost of a larger Genset
(Wye Delta)
Variable
VFD / VSD
June 2012
Variable
Reduced Voltage Starters
•
3000 kVA
Load Scenario: (2) 420 HP motors & (1) 150 kW Resistive load
D.O.L.
VSD
Autotransformer 80%
Autotransformer 65%
Autotransformer 50%
Wye Delta
Reactance 80%
Resistance 80%
Paralleled (2) gensets
880 kVA
June 2012
Soft Starter
Unloaded, Low Inertia Motors
• Low Inertia, 3-Phase Motors can be sized with a 15% reduction in
Starting kW (SkW) by deselecting the ‘Motor starting under load’
checkbox
• Low inertia motors
– brake, adjustable, automotive, servo, explosion proof, pump, brushless
DC, metric, multispeed, washdown & vector motors
– suitable for use with machine tools, conveyors, speed reducers,
hoists,...
June 2012
Unloaded, Low Inertia Motors
June 2012
Non-linear loads
• Create harmonics and voltage distortion
– Degrades performance of genset
• % of voltage distortion is critical in data center applications
• Alternator must be properly sized to limit voltage distortion
to acceptable level
• Types of non-linear loads:
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June 2012
Uninterruptible Power Supply (UPS)
Battery Charger
Elevator
Variable Frequency Drive Motors – VFD (60 Hz)
Variable Speed Drive Motors – VSD (50 Hz)
Non-linear loads, Filters & Pulse Rectifiers
• To offset unfavorable effects of non-linear loads
– Upsize alternator vs. recommend higher rated genset
– Add filters or increase genset’e pulse rectifier count
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6 pulse to 12-18-or-24 pulse
Reduces harmful effects of non-linear loads
Extends alternator life (avoids distortion overheating)
Maintains or improves power quality
– Can allow for a smaller ekW/kVA rated genset
• Potential to reduce initial purchase cost
June 2012
Non-linear loads, Filters & Pulse Rectifiers
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Filters, Loads with Filter Option
– Some converter type non-linear loads can be fitted with an electronic filter that mitigates
the effect of the non-linear load as seen by the alternator. These filters, can be
expensive, but if non-linear load is controlling the alternator size, the cost of the filter
may be more than offset by the savings from a smaller genset
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Air Conditioning
Battery Charger
Centrifugal Pump
Elevator
Motor (3-Phase)
UPS
VFD/VSD
X
VFD/VSD
X
VFD/VSD
X
Pulses, Loads with Pulse Option
– Many loads contain AC to DC converters, and these converters may trigger 6, 12, 18 or
24 times per electrical cycle; this is referred to as their pulse count. Lower pulse
devices are generally less costly, but also impose a higher non-linear load on the
alternator. More non-linear load (lower pulse count) requires a higher alternator
capacity
Air Conditioning
Battery Charger
Centrifugal Pump
Elevator
Motor (3-Phase)
UPS
Motor(Single Phase)
VFD/VSD
X
VFD/VSD
X
VFD/VSD
X
X
June 2012
Filters & Pulse
Rectifiers
• UPS load, 6-Pulse & No Filter
– C27 / 3412
• 937.5 kVA
• 1052.6 TkVA
• UPS load, 6-Pulse with Filter
– C27 / 3412
• 875 kVA
• 986.8 TkVA
June 2012
Filters & Pulse Rectifiers
• UPS load, 24-Pulse & No Filter
– C18
• 687.5 kVA
• 866.9 TkVA
June 2012
Energy Efficiency Ratio on Air Conditioning
• 6 EER – 1250 kVA C32
• 11 EER – 562 kVA C15
• 20 EER – 437 kVA C15
3-Phase AC
6-20 EER
6 EER
1-Phase AC
11 EER
20 EER
June 2012
Volts/Hz Optimization
• Voltage regulator
optimization
(3:1 slope)
– low frequency dip,
high voltage dip
• (e.g. 10%, 35%)
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motor loads
footprint
purchase cost
fuel cost
gen-set shipping
weight / cost
CDVR benefit, all Gensets !
June 2012
@Site Voltage (Amps)
• Loads w/ Amps
Adjustment
– 3-phase Motors
(LRA)
– 3-Phase Air
Conditioning (LRA)
– Single Phase AC
– Centrifugal Pump
(LRA)
– Lighting
– Resistive
– Office Equipment
– Medical
– Elevator
– Induction Furnace
June 2012
Genset phase voltage = 277V
Load voltage = 240V
200V / 277V * 200A = 174A
Ratio 240/277 = 0.87
200 Amp load adjusted to 174 Amp
Load Factor (Duty Point)
• Customer coal based power plant of 4 x 135 MW capacity
– Total running load of power plant = 12 /13 MW. Size of the UAT itself is only 16
MVA.
– Competition recommended (7) 3000 KVA engines. SpecSizer recommended
(8) engines.
June 2012
Load Factor (Duty Point)
•
Customer coal
based power plant
of 4 x 135 MW
capacity
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June 2012
Total running load
of power plant =
12 /13 MW. Size
of the UAT itself is
only 16 MVA.
Competition
recommended (7)
3000 KVA
engines.
SpecSizer
recommended (8)
engines.
19 total customer loads. Per
spec, most loads’ Duty Point
can be reduced from 100% to
75%. Reduced sizing from (8)
to (6) 3100 kVA gensets.
Help
• Help Topics
– Menu bar
• SME Help File
– On Power Net (for CAT Dealers)
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June 2012
SpecSizer landing page
Large 3-Phase Motors
Transformers
Sustained Voltage Dip
Questions?
• To order SpecSizer
– Cat.com
June 2012
http://www.cat.com/powergeneration/specsizer
Hands-On Training
•
Optional: Participants create SpecSizer files for Competitive Sizing Options.
– Instructor review Sizing Files with Participants
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•
Restrictive Fdip / Vdip
Wizard
– 20 Steps, Optimum step
•
Motor Starting
– Reduced Voltage Starters
•
•
•
Motor Starting, Low Inertia Motors
Non-linear loads, Filters & Pulse Rectifiers
Efficiency, Air Conditioners
– EER & SEER
•
•
•
Voltage Regulator Optimization
@Site Voltage (Amps)
Load Factor (Duty Point)
June 2012
Thank You
Steven Baker
EP Commercial Marketing