Genset Sizing with SpecSizer

Steven Baker
EP Commercial Marketing
June 2012
 SpecSizer Value
• Accurately sized gen-sets
– Perform efficiently
Least Cost
– Meet site operating demands Installation

• Improperly sized gen-sets

– Adds cost
– Poor performance
– Undersize
• Additional gen-sets to meet job site Under-sizing

requirements Over-sizing

• 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
 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

June 2012
 SpecSizer Performance Capability
Primary:
• Influencing Parameters 1 Engine Design & Displacement turbo, fuel injector

Engine
2 Engine Power Density (BMEP at price list rating)
Genset Transient Response 3 Fuel (liquid vs. gas)
4 Alternator Design & D²L (e.g. Kgmotor & Kgblock) speed rpm / frequency (50Hz / 60Hz)

Alternator
5 Voltage Regulator
6 a Slope / Gain
7 b Knee frequency
8 c PID leads / lags
9 Load Scenario
• Project Parameters: 10 a Type & size of loads

Site
Conventional vs. Frequency 11 b Power Factor (e.g. lights vs. motor)
12 Site Ambient conditions & Cooling Capacity radiator size, fan speed
Limited Sizing Secondary:

aftercooler, compression ratio with A-

13 Engine Governor Design B-C series engine redesign, enclosure
alternator voltage adjustment (dial
14 GenSet Inertia (Engine & Alternator) down e.g. 480V to 416V)
• SpecSizer 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.

Wizard Icon

June 2012
 Set Your Preferences
• Menu bar
– File, Preferences
– (8) Languages

June 2012
 Help is Available • Menu bar
• Help (Project Parameters) – Help Topics
– Generator Set Duty
– Sizing Methodology
– Emissions Certification

June 2012
 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

• Linear & Non-Linear Loads

– 3-phase Motor (w/ VFD/VSD, Soft Starter)
– Single phase Motor
– 3-Phase Air Conditioning (w/ VFD/VSD, Soft Starter) Range < 40%
– Single Phase Air Conditioning
– Centrifugal Pump (w/ VFD/VSD, Soft Starter)
– Lighting
• Fluorescent, Incandescent, Gas Discharge, Ultraviolet
– Resistive
– Office Equipment Non-Linear Loads
– UPS
– Battery Charger
– Medical
– Elevator
– Induction Furnace (w/ Thyristor)
– Welder
– Miscellaneous (w/ Pulse Rectifier)

June 2012
 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
– 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

June 2012
 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

• 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
Step#1 Motor load with 10% Fdip
moved to Step#2

June 2012
 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 Variable

June 2012
 Reduced Voltage Starters
• Load Scenario: (2) 420 HP motors & (1) 150 kW Resistive load

3000 kVA D.O.L.

VSD

Autotransformer 80%

Autotransformer 65%

Autotransformer 50%

Wye Delta

Reactance 80%

Resistance 80%
Paralleled (2) gensets

880 kVA Soft Starter

June 2012
 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:
– Uninterruptible Power Supply (UPS)
– Battery Charger
– Elevator
– Variable Frequency Drive Motors – VFD (60 Hz)
– Variable Speed Drive Motors – VSD (50 Hz)
June 2012
 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

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
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 3-Phase AC

• 11 EER – 562 kVA C15
• 20 EER – 437 kVA C15

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%)
– 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 Genset phase voltage = 277V
Load voltage = 240V
(LRA)
200V / 277V * 200A = 174A
– Lighting
Ratio 240/277 = 0.87
– Resistive
200 Amp load adjusted to 174 Amp
– Office Equipment
– Medical
– Elevator
– Induction Furnace

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. SpecSizer 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 19 total customer loads. Per
of the UAT itself is spec, most loads’ Duty Point
only 16 MVA. can be reduced from 100% to
– Competition 75%. Reduced sizing from (8)
recommended (7) to (6) 3100 kVA gensets.
3000 KVA
engines.
SpecSizer
recommended (8)
engines.

June 2012
 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

June 2012
 Questions?
• To order SpecSizer
– Cat.com http://www.cat.com/powergeneration/specsizer

June 2012
 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)

June 2012
Thank You

Steven Baker
EP Commercial Marketing