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Genset Sizing with SpecSizer

Genset Sizing with SpecSizer. Steven Baker EP Commercial Marketing. SpecSizer. Under-sizing Over-sizing. SpecSizer Value. Accurately sized gen-sets Perform efficiently Meet site operating demands Improperly sized gen-sets Adds cost Poor performance Undersize

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Genset Sizing with SpecSizer

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  1. Genset Sizing with SpecSizer Steven Baker EP Commercial Marketing

  2. SpecSizer

  3. Under-sizing Over-sizing SpecSizer Value • Accurately sized gen-sets • Perform efficiently • Meet site operating demands • 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) Least Cost Installation

  4. SpecSizer Performance to Standards • Specifying generator sets for voltage and frequency transient response • NFPA 110 • North American spec • Generator must start, pick up full-rated 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

  5. SpecSizer Performance Capability • Influencing Parameters Genset Transient Response • Project Parameters: Conventional vs. Frequency Limited Sizing • SpecSizer Help

  6. 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

  7. Set Your Preferences • Menu bar • File, Preferences • (8) Languages

  8. Help (Project Parameters) Generator Set Duty Sizing Methodology Emissions Certification Menu bar Help Topics Help is Available

  9. 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

  10. 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

  11. Non-Linear Loads Load Scenario • Linear & Non-Linear Loads • 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 • Fluorescent, Incandescent, Gas Discharge, Ultraviolet • Resistive • Office Equipment • UPS • Battery Charger • Medical • Elevator • Induction Furnace (w/ Thyristor) • Welder • Miscellaneous (w/ Pulse Rectifier) Range < 40%

  12. 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)

  13. 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

  14. Generator Set Selection • Starting & Selection Analysis • Genset Transient Capability • Factory genset transient performance tests • Volts/Hz Optimization C175 3000 kVA vs. 3516B 2500kVA

  15. Generator Set Selection • Go to Best Fit Genset • Guide Spec • MS Word doc, editable • Paralleling • Customer/Dealer Sales Support Links

  16. Generator Set Selection • Note provided:Why the next smallest genset fails Load requirement Loads require 1613.9 RkW 2500kVA Genset capable of 1497.8 RkW when derated

  17. Generator Set Selection • Alternator Frame Options Alternative Genset (with capable alternator) to sized genset in Inventory? Table provides Cat dealer options.

  18. Technical Tab • Sizing Report • Load Analysis Summary • Generator Set • Engine Technical Data • Alternator Technical Data • Load Report • Permitted Dip • Predicted Dip • Load Analysis • Maximum Step and Maximum Peak SkVA/SkW • Final Running kVA/kW • Step transient performance graph • Transient Performance Report • Step Fdip and Vdip • Step Transient Performance Graph • Block Load Transient Performance Table • Block Load Transient Performance Graph

  19. SpecSizer - Load Transients & Genset Transients Load Transients Genset Transients

  20. 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 Sizing Competitive Gensets

  21. 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) Competitive Sizing Options

  22. 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 • If possible - sequence restrictive loads later in load scenario • e.g. UPS load • Must adhere to specification

  23. Restrictive Fdip / Vdip Resized:2500kVA 3516  1750kVA 3512B Step#1 Motor load with 10% Fdip moved to Step#2

  24. Restrictive Fdip / Vdip 1750kVA 3512B

  25. 4 Steps  15 Steps 20 Step Wizard & Optimum Step 3512 (1137kVA)  C18 (545 kVA)

  26. 64% 80% tap (Wye Delta) Variable Variable VFD / VSD Reduced Voltage Starters SpecSizer’s 3-phase Motor Reduced Voltage Options & Respective Torque Limitations • Reduced Voltage Starter • Cost-benefit analysis • Cost of Starter • vs. • Cost of a larger Genset

  27. D.O.L. VSD Autotransformer 80% Autotransformer 65% Autotransformer 50% Wye Delta Reactance 80% Resistance 80% Paralleled (2) gensets Soft Starter Reduced Voltage Starters • Load Scenario: (2) 420 HP motors & (1) 150 kW Resistive load 3000 kVA 880 kVA

  28. 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,...

  29. Unloaded, Low Inertia Motors

  30. 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: • Uninterruptible Power Supply (UPS) • Battery Charger • Elevator • Variable Frequency Drive Motors – VFD (60 Hz) • Variable Speed Drive Motors – VSD (50 Hz)

  31. 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 • 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

  32. Non-linear loads, Filters & Pulse Rectifiers • 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 • 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

  33. 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

  34. Filters & Pulse Rectifiers • UPS load, 24-Pulse & No Filter • C18 • 687.5 kVA • 866.9 TkVA

  35. 3-Phase AC 6 EER 11 EER 6-20 EER 20 EER 1-Phase AC Energy Efficiency Ratio on Air Conditioning • 6 EER – 1250 kVA C32 • 11 EER – 562 kVA C15 • 20 EER – 437 kVA C15

  36. Volts/Hz Optimization • Voltage regulator optimization (3:1 slope) • low frequency dip, high voltage dip • (e.g. 10%, 35%) • motor loads • footprint • purchase cost • fuel cost • gen-set shipping weight / cost CDVR benefit, all Gensets !

  37. @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 Genset phase voltage = 277V Load voltage = 240V 200V / 277V * 200A = 174A Ratio 240/277 = 0.87 200 Amp load adjusted to 174 Amp

  38. 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.

  39. 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. 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.

  40. Help • Help Topics • Menu bar • SME Help File • On Power Net (for CAT Dealers) • SpecSizer landing page • Large 3-Phase Motors • Transformers • Sustained Voltage Dip

  41. Questions? • To order SpecSizer • Cat.com http://www.cat.com/powergeneration/specsizer

  42. Hands-On Training • Optional: Participants create SpecSizer files for Competitive Sizing Options. • Instructor review Sizing Files with Participants • 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)

  43. Thank You Steven Baker EP Commercial Marketing

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