UNDERSTANDING GENERATOR SET RATING DEFINITIONS. Nick Paolo, Regional Sales Engineer MTU Onsite Energy

Transcription

1 UNDERSTANDING GENERATOR SET RATING DEFINITIONS Nick Paolo, Regional Sales Engineer MTU Onsite Energy

2 AGENDA 01. ISO Standard 02. Manufacturer Allowances 03. Exhaust Emissions 04. Specific Industry Ratings 05. Conclusion

3 01 ISO STANDARD What does the ISO standard define?

4 ISO STANDARD INTRODUCTION Where do our ratings come from? : Applications, Ratings, & Performance : Engines : AC generators for gensets : Control gear & Switchgear : Generating Sets : Test Methods : Technical Declarations for Specifications and Design : Measurement and Evaluations of Mechanical Vibrations : Measurement of Airborne Noise : Emergency Power Supply to Safety Services

5 ISO STANDARD RATINGS What ratings does ISO define? Four types of ratings 1. Emergency Standby Power (ESP) 2. Prime Power (PRP) 3. Limited-Time Running Power (LTP) 4. Continuous Power (COP)

6 ISO STANDARD CRITERIA # 1: ANNUAL RUN-TIME Rating Type Expected Annual Runtime Emergency Standby Power (ESP) Prime Power (PRP) Limited-Time running Power (LTP) Continuous Power (COP) 200 hours Unlimited 500 hours Unlimited The expected annual run-time criteria establishes the annual hourly usage expectation

7 ISO STANDARD CRITERIA # 2: LOAD VARIABILITY Rating Type Expected Annual Runtime Emergency Standby Power (ESP) Prime Power (PRP) Limited-Time running Power (LTP) Continuous Power (COP) 200 hours Unlimited 500 hours Unlimited Load Variability Variable Variable Undefined Constant Variable Load Example Constant Load Example The load variability criteria determines the load profile expectation

8 ISO STANDARD CRITERIA #3: LOAD FACTOR Rating Type Expected Annual Runtime Emergency Standby Power (ESP) Prime Power (PRP) Limited-Time running Power (LTP) Continuous Power (COP) 200 hours Unlimited 500 hours Unlimited Load Variability Variable Variable Undefined Constant Average Load Factor 70% 70% 100% 100% The load factor criteria determines the expected average load over any 24 hour operating period

9 ISO STANDARD LOAD FACTOR EXAMPLE Reference Material Power Output (kw) Time (hours) kw / hrs Totals 24 15, kW PRP rated unit 24 hour load profile shown 15,600 kw / hrs. accumulated Average Load = 15,600 kw * hrs. 24 hrs. = 650 kw 650 kw Average Load Factor = = 65% 1000 kw

10 02 MANUFACTURER ALLOWANCES How do manufacturer s differ from each other?

11 MANUFACTURER ALLOWANCES NET POWER vs. GROSS POWER What is the difference? Net Power Rating: The maximum amount of power from the genset available, after subtracting electrical power it uses during operation Gross Power Rating: The maximum amount of power from the genset available, without consideration for electrical power it uses during operation

12 MANUFACTURER ALLOWANCES NET POWER vs. GROSS POWER EXAMPLE Gross Power Output with electronically powered cooling fans

13 MANUFACTURER ALLOWANCES NET POWER vs. GROSS POWER EXAMPLE Net Power Output with electronically powered cooling fans

14 MANUFACTURER ALLOWANCES NET POWER vs. GROSS POWER EXAMPLE Net Power Output with belt driven cooling fans

15 MANUFACTURER ALLOWANCES NET POWER vs. GROSS POWER EXAMPLE Competitor Published Ratings w/o Fan Power Caterpillar C175-16V 3.25MW Standby Rated Caterpillar C175-20V 3.5 4MW Standby Rated Cummins DQLE (QSK 78 powered) 2.5MW Standby rated Cummins DQLF (QSK 78 powered) 2.75MW Standby rated Cummins QSK 95 (in development) 3.5MW Standby rated

16 MANUFACTURER ALLOWANCES OVERLOAD CAPABILITY What is overload? % Load 100% 80% 60% 40% 20% 0% Hours Overload in the power generation industry is defined as additional power available for a short amount of time Commonly offered as 110% of the PRP rating Typically utilized for load fluctuations

17 MANUFACTURER ALLOWANCES OVERLOAD CAPABILITY DIFFERNCES How do manufacturer's differ? Annual operation limit at 110%: Less than 87 hours (1% of year) Less than 25 hours

18 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE How are gensets sized? The inherent nature of different electrical loads needs to be understood. Motors & Transformers have a large current demand (referred to as in-rush) for a short period of time when initially connected Most other loads do not incur the same in-rush demand

19 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE Scenario # 1 Started in one step across the line Lowest cost starting method Minimum Genset Size: 550kW 50% Average Load Factor Loads: o (6) 25hp NEMA code G motors o 150kW of incandescent lighting

20 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE Scenario # 2 Started in two steps across the line Increased cost starting method Minimum Genset Size: 400kW 69% Average Load Factor Loads: o (6) 25hp NEMA code G motors o 150kW of incandescent lighting

21 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE Scenario # 3 Soft-started in one step Most costly starting method Minimum Genset Size: 350kW 79% Average Load Factor Loads: o (6) 25hp NEMA code G motors o 150kW of incandescent lighting

22 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE Scenario #1 Peak Power 525kW Running Power 275kW Load Factor 50% Genset Size 550kW Scenario #2 Peak Power 375kW Running Power 275kW Load Factor 69% Genset Size 400kW Scenario #3 Peak Power 275kW Running Power 275kW Load Factor 79% Genset Size 350kW

23 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE

24 MANUFACTURER ALLOWANCES LOAD FACTOR REAL WORLD ADVANTAGE As more efficient starting methods are utilized Size of the genset is decreased due to decreased in-rush Costs go down significantly Genset load factor is increased (if allowed by manufacturer) Rating ESP PRP COP MTU Load Factor 85% 75% 100% ISO Minimum 70% 70% 100%

25 MANUFACTURER ALLOWANCES MAXIMUM ANNUAL ESP RUN-TIME Does my genset have an annual run-time limit? No limit defined by ISO for Emergency Standby Power 200 hour annual recommendation Some genset manufacturer s give a hour annual limit MTU OE gensets have a 500 hour annual recommendation With no annual limit Just follow the standard maintenance program

26 MANUFACTURER ALLOWANCES TIME BEFORE OVERHAUL (TBO) Rating Hours ESP 6000 PRP 10,000-15,000 COP 21,000 No TBO defined by ISO for any rating Some manufacturer s do not publish a defined maintenance schedule with time before overhaul clearly shown Without TBO defined, products, quality, and ratings cannot be compared MTU OE engines were initially designed with defined TBO requirements

27 03 EXHAUST EMISSIONS How do exhaust emissions impact the generator set rating?

28 EXHAUST EMISSIONS USA GENSET EMISSION CONSIDERATIONS USA Exhaust emission requirements for gensets come from three different levels Facility Complexity Regional Federal The federal emissions are the starting point for consideration

29 EXHAUST EMISSIONS FEDERAL ENGINE CLASIFICATION Environmental Protection Agency (EPA) Requirements for gensets can be broken into three categories 1. Stationary Emergency 2. Stationary Non-Emergency 3. Non-Road Mobile Machinery

30 EXHAUST EMISSIONS IMPACT TO GENSET RATINGS Genset Rating Emergency Standby EPA Classification Emergency Engines Exhaust emission requirements are commonly thought to be officially related to the genset ratings Not true! Prime Power Non-Emergency Engines Genset ratings are based on ISO & the genset manufacturer's guidelines Ratings & EPA emission class can be cross-applied

31 EXHAUST EMISSIONS EMERGENCY REQUIREMENTS EMERGENCY DIESEL ENGINES Stationary Emergency Category Current requirements breakdown into three Tiers <50hp Engines : Tier hp: Engines: Tier 3 >750hp Engines: Tier 2

32 EXHAUST EMISSIONS NON-EMERGENCY REQUIREMENTS NON-EMERGENCY DIESEL ENGINES Stationary Non- Emergency Category Tier 4

33 EXHAUST EMISSIONS MOBILE REQUIREMENTS NON-ROAD MOBILE DIESEL ENGINES Mobile Classification Current requirements All Tier 4

34 EXHAUST EMISSIONS MOBILE REQUIREMENTS NON-ROAD MOBILE DIESEL ENGINES Mobile Classification (continued) TPEM or mobile flexing allows previous certified Tier

35 EXHAUST EMISSIONS FEDERAL CATEGORY EXCEPTIONS Class General Usage Exceptions & Notes Emergency Stationary When normal source (utility) is not available Non- Emergency Unlimited 100 hours maint. & testing Requires inducement** Non-Road Mobile Machinery Unlimited use in mobile applications Must move facilities once per year to be considered mobile Transition Plan for Engine Manufacturer's (TPEM) allowed*** *Currently being reviewed by EPA ** Inducement: Situation where engine must reduce power or shut down when emission requirements are not met due to product malfunction, tampering, and poor quality or low diesel emission fluid, etc. ***TPEM allows for previous EPA Tier certification to be used for limited amount of time

36 EXHAUST EMISSIONS NON-EMERGENCY DECISION Should I buy just what I need? (Tier 2) Why does a customer want a Tier 4? Or should I spend more for a Tier 4 certified genset so I can do utility programs? 1. Participate in utility programs >50 hours per year (**currently being reviewed by EPA) 2. Run where no utility power exists 3. Party influenced specification to require Tier 4 (even though not required)

37 EXHAUST EMISSIONS NON-EMERGENCY DECISION Should I buy just what I need? (Tier 2) What else could the customer do with a certified Tier 4 product? Or should I spend more for a Tier 4 certified genset so I can do utility programs? 1. Comply to local requirements (if aligned) Certification may not be required! 2. Meet Best Available Control Technology (BACT) requirements Certification not required! 3. Promote a green reputation Certification not required!

38 EXHAUST EMISSIONS NON-EMERGENCY DECISION Should I buy just what I need? (Tier 2) Why might a customer not want a certified Tier 4 product? Or should I spend more for a Tier 4 certified genset so I can do utility programs? 1. Price Competitor market price levels 50-70% above Tier 2 2. Inducement Concerns EPA required shut-downs add risk to mission critical applications

39 EXHAUST EMISSIONS NON-EMERGENCY DECISION ESP ESP w/utility Program Prime Power / Continuous Power T4 Certification Specified? no Want a green reputation? no yes yes Payback good? no yes How would a customer make this decision? Local Emission Requirements? yes Certified best solution? yes no no Tier 2 Tier 2 + After-Treatment Tier 4 Certified

40 EXHAUST EMISSIONS REGIONAL REQUIREMENTS Various regional requirements apply Can be defined as: 1. State Agencies (DoE) 2. Regional Bureaus

41 EXHAUST EMISSIONS REGIONAL REQUIREMENTS Department of Environment (DoE) Requirements Each State has a Department of Environment (DoE) that is responsible to protect and improve air quality Regarding stationary engine operation, a DoE will: Define usage classifications & Issue Permits Emergency or Non-Emergency based on usage Determine method & timeframe for emission measurements Determine more strict requirements than EPA

42 EXHAUST EMISSIONS FACILITY LIMITS Title V Permitting The Federal Clean Air Act requires Title V permits for facilities that emit: >100 tons annually of any one Hazardous Air Pollutant (HAP) >25 tons annually of any combination of HAPs Title V permitting is often not considered due to bad publicity & costs Multiple diesel gensets at one site without after-treatment can require Title V permitting (example: Data Centers) Any other major source of emissions on site are also included in calculating the facility output (example: Boilers)

43 EXHAUST EMISSIONS FACILITY LIMITS Facility Limits (continued) One 16V4000G83L 2500 kwe Standby Rating Tier 2 Certified for Emergency Use Each unit has the Potential to Emit (PTE) Facility Limit: 5615 hours per year because of NOx emission

44 EXHAUST EMISSIONS FACILITY LIMITS Facility Limits (continued) Twenty-eight 16V4000G83L s 2500 kwe Standby Rating Tier 2 Certified for Emergency Use Each unit has the Potential to Emit (PTE) Facility Limit: 200 hours per year because of NOx emission

45 EXHAUST EMISSIONS FACILITY LIMITS Non-Attainment Areas Non-Attainment Areas are defined as counties that do not meet the National Ambient Air Quality Standards (NAAQS) 44 of 50 (88%) states have designated Non-Attainment Areas As population density grows, Non-Attainment Areas will increase

46 EXHAUST EMISSIONS FACILITY LIMITS Non-Attainment Areas The Clean Air Act requires that any State with Non-Attainment Areas must develop a State Implementation Plan (SIP) to correct the problem. SIP s may include: Reduced Facility limits (for Title V permitting) Example: Instead of 100 tons/year of a HAP for Title V permits, limit is reduced to 50 tons (serious) or 10 tons (extreme)

47 EXHAUST EMISSIONS FACILITY LIMITS Facility Limits (continued) Twenty-eight 16V4000G83L s in extreme Non-Attainment area 2500 kwe Standby Rating Tier 2 Certified for Emergency Use Each unit has the Potential to Emit (PTE) Facility Limit: 20 hours per year because of NOx emission

48 EXHAUST EMISSIONS SUMMARY Exhaust emissions do not follow ISO ratings Treat them separately Exhaust emissions can be broken into 3 categories Federal Limits (EPA) Regional Limits (State / local authority) Facility Limits (site specific) Certified Tier 4 equipment is not always needed Help the customer determine what they really need Often customers are confused Competitors will try to influence specifications

49 04 SPECIFIC INDUSTRY RATINGS What are some examples of rating requests that do not fit into ISO standard definitions?

50 SPECIFIC INDUSTRY RATINGS DATA CENTERS Data Centers and other mission critical applications must have reliable emergency backup power in case of outages To standardize performance classes of data center uptime, an organization was created- The Uptime Institute performance standard is the globally accepted design standard for data centers

51 SPECIFIC INDUSTRY RATINGS UPTIME INSTITUTE TIER CLASSIFICATION Tier Requirement Tier I Tier II Tier III Tier IV Source System Component Redundancy (power & cooling) System N N+1 System + System Multiple N+1 Distribution Paths 1 1 active and 1 alternate 2 active Concurrently Maintainable No Yes Fault Tolerance (single event) No Yes Compartmentalization No Yes Continuous Cooling Load Density Dependent Yes (Class A) Availability 99.67% 99.75% 99.98% 99.99% The Uptime Institute tier certification refers to the data centers' infrastructure that directly affects the computer room operation & uptime The certifications are awarded in four Tier levels

52 SPECIFIC INDUSTRY RATINGS TIER COMPARISON TO ISO RATINGS Rating Type Emergency Standby Power (ESP) ISO Ratings Prime Power (PRP) Limited-Time running Power (LTP) Continuous Power (COP) Uptime Institute Requirements Tier I & II Tier III & IV Expected Annual Run-time 200 hours Unlimited 500 hours Unlimited 200 hours Unlimited Load Variability Average Load Factor Variable Variable Undefined Constant Variable Variable 70% 70% 100% 100% Undefined 100% Usage Back-up Power No reliable utility applications Grid Programs Power Stations Back-up Power Back-up Power

53 05 CONCLUSION How do all these factors impact one another?

54 CONCLUSION THE BALANCING ACT Specific Industry Ratings Manufacturer Allowances ISO Standard Genset Purchaser EPA Exhaust Emissions Customers The key to supporting the customer is an understanding of all factors!

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56 ANY QUESTIONS? THANK YOU FOR YOUR ATTENTION