Genset Sizing with Spec Sizer Steven Baker EP

Genset Sizing with Spec. Sizer Steven Baker EP Commercial Marketing

June 2012

Spec. Sizer 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

Spec. Sizer 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 – ISO 8528 -5 • world-wide standard • defines operating limit values for performance classes G 2 -G 4, for critical genset sizing parameters • transient frequency deviation (dip), transient voltage (dip), and frequency and voltage recovery time June 2012

Spec. Sizer Performance Capability • Influencing Parameters Genset Transient Response • Project Parameters: Conventional vs. Frequency Limited Sizing • Spec. Sizer Help June 2012

Getting Started • Select – New 3 -Phase or Single Phase Project – Open Existing Project – Use Wizard Tip: Easier to use the Wizard icon for 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/spec sizer June 2012

Project Parameters Features • Standby Caterpillar & Olympian – Caterpillar 300 – 3100 k. VA • C 175 -20 (5000 k. VA) – Olympian 13. 8 – 700 k. VA • Best Fit Transient Performance – CDVR @ Std vs. Optimized VR Slope • Percent of Intermittent Motors – diversity factor for competitive sizing June 2012

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 – – – – – June 2012 Resistive Office Equipment UPS Battery Charger Medical Elevator Induction Furnace (w/ Thyristor) Welder Miscellaneous (w/ Pulse Rectifier) Range < 40% Non-Linear Loads

Generator Set Selection • Sizes & Selects Genset • Load Analysis Summary – Algorithms – Site Conditions + Load Scenario – Inrush, Running & Non. Linear k. W & k. VA • Load dialog inputs • Load sequencing • % Genset Rated Capacity (Ek. W) 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 C 175 3000 k. VA vs. 3516 B 2500 k. VA • Volts/Hz Optimization 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 provide d: Why the next smallest genset fails Loads require 1613. 9 Rk. W 2500 k. VA Genset capable of 1497. 8 Rk. W 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 – – • Load Analysis Summary Generator Set Engine Technical Data Alternator Technical Data Load Report – Permitted Dip – Predicted Dip – Load Analysis • • Maximum Step and Maximum Peak Sk. VA/Sk. W Final Running k. VA/k. W Step transient performance graph Transient Performance Report – – June 2012 Step Fdip and Vdip Step Transient Performance Graph Block Load Transient Performance Table Block Load Transient Performance Graph

Spec. Sizer - Load Transients & Genset Transients Load Transients Genset Transients June 2012

Sizing Competitive Gensets • Accurate Sizing – Continuous development since 1/2006 – NPI updates 2 x-3 x 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 • If possible - sequence restrictive loads later in load scenario – e. g. UPS load – Must adhere to specification June 2012

Restrictive Fdip / Vdip Resized: 2500 k. VA 3516 1750 k. VA 3512 B June 2012 Step#1 Motor load with 10% Fdip moved to Step#2

Restrictive Fdip / Vdip 1750 k. VA 3512 B June 2012

20 Step Wizard & Optimum Step 4 Steps 15 Steps 3512 (1137 k. VA) C 18 (545 k. VA) June 2012

Reduced Voltage Starters Spec. Sizer’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) VFD / VSD June 2012 Variabl e

Reduced Voltage Starters • Load Scenario: (2) 420 HP motors & (1) 150 k. W Resistive load 3000 k. VA D. O. L. VSD Autotransformer 80% Autotransformer 65% Autotransformer 50% Wye Delta Reactance 80% Resistance 80% Paralleled (2) gensets 880 k. VA June 2012 Soft Starter

Unloaded, Low Inertia Motors • Low Inertia, 3 -Phase Motors can be sized with a 15% reduction in Starting k. W (Sk. W) 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: – – – 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 • 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 June 2012

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 June 2012

Filters & Pulse Rectifiers • UPS load, 6 -Pulse & No Filter – C 27 / 3412 • 937. 5 k. VA • 1052. 6 Tk. VA • UPS load, 6 -Pulse with Filter – C 27 / 3412 • 875 k. VA • 986. 8 Tk. VA June 2012

Filters & Pulse Rectifiers • UPS load, 24 -Pulse & No Filter – C 18 • 687. 5 k. VA • 866. 9 Tk. VA June 2012

Energy Efficiency Ratio on Air Conditioning • 6 EER – 1250 k. VA C 32 • 11 EER – 562 k. VA C 15 • 20 EER – 437 k. VA C 15 6 EER 11 EER 20 EER June 2012 3 -Phase AC 6 -20 EER 1 -Phase AC

Volts/Hz Optimization • Voltage regulator optimization (3: 1 slope) – low frequency dip, high voltage dip • (e. g. 10%, 35%) – – – June 2012 motor loads footprint purchase cost fuel cost CDVR benefit, all gen-set Gensets ! shipping weight / cost

@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 = 277 V Load voltage = 240 V 200 V / 277 V * 200 A = 174 A 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. Spec. Sizer recommended (8) engines. June 2012

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. Spec. Sizer recommended (8) engines. June 2012 19 total customer loads. Per spec, most loads’ Duty Point can be reduced from 100% to 75%. Reduced sizing from (8) to (6) 3100 k. VA gensets.

Help • Help Topics – Menu bar • SME Help File – On Power Net (for CAT Dealers) • • June 2012 Spec. Sizer landing page Large 3 -Phase Motors Transformers Sustained Voltage Dip

Questions? • To order Spec. Sizer – Cat. com June 2012 http: //www. cat. com/powergeneration/s pecsizer

Hands-On Training • Optional: Participants create Spec. Sizer 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) June 2012

Thank You Steven Baker EP Commercial Marketing