Generators and Emergency Preparedness Jess Treadway, Caterpillar - - PDF document

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Feb 15, 2023 343 likes •542 views

10/8/19 Caterpillar: Confidential Green Generators and Emergency Preparedness Jess Treadway, Caterpillar Jonathan Rall, Ring Power Topics Ratings and Usage ISO 8528 Caterpillar EPA Design for Emergency Preparedness

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Caterpillar: Confidential Green

Generators and Emergency Preparedness

Jess Treadway, Caterpillar Jonathan Rall, Ring Power

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Topics

  • Ratings and Usage

§ ISO 8528 § Caterpillar § EPA

  • Design for Emergency Preparedness

§ Facility design § The most common issues § Designing for maintenance

  • Being Ready for the Storm

§ Extended outages § Maintenance considerations § What to know and have

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Ratings and Usage

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Why are Ratings Important?

  • Over aggressive use of ratings could result in accelerated wear and unplanned

downtime

  • Over conservative use of ratings removes value, increases cost, can cause

performance issues and potentially lead to maintenance issues.

  • Major Considerations

§ Number of expected run hours per year. § Average load versus Peak load § Ultimate Application: Is the generator set the normal source or emergency source? Is it normally paralleled with other sources?

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Ratings Confusion in Specifications

Specification: Section 5.A “Generator shall be rated 2 MW Standby, 1825 kW prime”

  • Ratings designed to help drive understanding between users, engineers, and

manufacturers

  • What is more important to the site?

§ Starting time and transient response? § Fuel consumption and time between overhauls?

  • Specifications such as this can drive unnecessary cost into projects

Key: What is the application of the generator set

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What is ISO8528?

  • International standard for diesel and gas generator sets
  • Intended to help understanding between manufacturer and customer
  • ISO 8528 defines four ratings

§ Continuous Power (COP) § Prime Power (PRP) § Limited-Time Running Power (LTP) § Emergency Standby Power (ESP) § Data Center Power (DCP)

Should be considered as a minimum standard for manufacturers

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Continuous Power (COP)

COP pow er (100%) stops for maintenance Time Power

COP Key Points

  • Unlimited Hours per year
  • Load 100% Nameplate
  • Constant Electrical Load

Definition: The maximum power which the generator set is capable of delivering continuously whilst supplying a constant electrical load when operated for an unlimited number of hours per year under the agreed operating conditions with the maintenance intervals and procedures being carried out as prescribed by the manufacturer.

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Prime Power (PRP)

Definition: The maximum power which the generator set is capable of delivering continuously whilst supplying a variable electrical load when operated for an unlimited number of hours per year under the agreed operating conditions with the maintenance intervals and procedures being carried out as prescribed by the manufacturer. The permissible average power output over 24hr of operation shall not exceed 70% of the PRP unless otherwise agreed by the engine manufacturer

PRP pow er (100%) Permissible average pow er Time Power Actual average pow er P1 P2 P3 P4 P5 P6 30% t1 t2 t3 t4 t5 t6 Stop

PRP Key Points

  • Unlimited Hours per Year
  • Not to exceed 70% average

load in 24 hours

  • Variable Electrical Load
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Limited-Time Power (LTP)

Definition: The maximum power available, under the agreed operating conditions, for which the generator set is capable of delivering for up to 500hr of operation per year with the maintenance intervals and procedures being carried out as prescribed by the manufactures Limited time running power at 100% is limited to a maximum of 500hrs per year

LTP pow er (100%) Time Power stop stop stop

LTP Key Points

  • Limited to 500 Hours per Year
  • Load 100% of Nameplate
  • Constant Electrical Load

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Emergency Standby Power (ESP)

Definition: The maximum power available during a variable electrical power sequence, under the stated

  • perating conditions, for which a generating set is capable of delivering in the event of a utility power outage
  • r under test conditions for up to 200hr of operation per year with the maintenance intervals and procedures

being carried out as prescribed by the manufacturer The permissible average power output over 24hr of operation shall not exceed 70% of the ESP unless

  • therwise agreed by the RIC engine manufacturer

ESP Key Points

  • Limited to 200 Hours per

year

  • Not to exceed 70% average

load in 24 hours

  • Variable Electrical Load

ESP pow er (100%) Permissible average pow er Time Power Actual average pow er P1 P2 P3 P4 P5 30% t1 t2 t3 t4 t5 Stop Stop Stop

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Data Center Power (DCP)

Released 2018 Definition: Data Center Power is the maximum power that a genset is capable of providing, at a variable or continuous load, for an unlimited number of hours. Depending on the site’s requirements & the availability of a reliable grid supply, it’s the responsibility of the genset manufacturer to define the level of power that the genset can supply to meet the requirement, including modification of hardware, software or maintenance

  • schedule. Note: An engine-driven ac generator is a reliable power source for a data center & can also be

used as back-up for a reliable grid. Prolonged paralleling to the grid is not permitted.

DCP Key Points

  • Capable of providing power for unlimited hours
  • Manufacturer reasonability to define power level

based off site requirements

  • Variable or Continuous Electrical Load

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Differences between ISO8528 Ratings and Cat Ratings

  • ISO8528 ratings: states average load factors and usage as hard limitations
  • Caterpillar ratings: average load factors and usage are not hard limitations,

rather guidance.

  • Additional differences on certain specific ratings

Cat Ratings versus ISO8528 Ratings

ISO8521 Rating Caterpillar Rating

Continuous (COP) Continuous Rating Prime Power (PRP) Prime Power (Exceeds PRP) Limited Time Running (LTP) Load Management (Exceeds LTP) Standby (Exceeds ESP) Mission Critical Standby (Exceeds ESP) Standby Mission Critical Standby Prime Power Emergency Standby (ESP) Data Center Power (DCP)

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Data Center Power (DCP) Coverage

  • Caterpillar does not have DCP ratings
  • Cover intentions of the ISO rating with existing Cat ratings

§ Standby/Mission Critical Standby

  • For areas where grid or other power source acts as normal power source
  • Can run for the duration of any outage

§ Prime

  • For areas where the generator sets are seen as the normal power source
  • Unlimited hours per year

Consult your local Cat Dealer or Cat representative to find the best product/rating for your requirements and location

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Emissions and Ratings

EPA Stationary Diesel Regulations

  • Set minimum emissions regulations for United States
  • Looks only at application of units, not nameplate rating

§ Tier 2/3: emergency use only – less strict emissions requirements but strict operational requirements § Tier 4 Final: non-emergency use – strict emissions requirements but no operational requirements

  • Generator set rating is not related to EPA application definition: EPA concerned with how long and for

what use the generator set is running when utility power is available.

§ Prime power rated generator sets can be emergency (Tier 2/3) § Standby rated generator sets can be non-emergency (Tier 4 Final)

Certain locations may have further run hour/emissions regulations

  • All states, counties, cities, and towns can have specific requirements: can be dependent on location,

fuel, number of units/other sources, etc

  • EPA sets minimum standard in US, but local regulations can set stricter limits for emergency and non-

emergency generator sets

  • Need to consult local AHJ
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Mobile vs Stationary

  • Mobile

§ Moves more than once in a 12 month period § Requires the use of EPA Tier 4 Final

  • Stationary

§ Emergency Standby: Tier 2/3 § Non-Emergency Standby: EPA Tier 4 Final

  • Definition of Emergency Standby

§ No limitation on actual run time (no normal power available) § 100 hours per year limit for non-emergency operation for stationary emergency gensets

  • Site Testing and Maintenance
  • Normal power frequency or voltage deviate 5% or greater below standard
  • Up to 50 hours per year:
  • Can be used for storm avoidance (no voltage or frequency deviation from normal power)
  • Cannot be used for peak shaving
  • Counts towards 100 hours per year limit

§ Operator must record use and reference to hours meter

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Design for Emergency Preparedness

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Engine Room Design Considerations

  • Basement- flooding
  • Good fresh air
  • Facilities change over time – restriction to intake air.

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Design to Maximize Product Reliability

The most common causes of failure to start:

  • Discharged batteries
  • Not in Auto/E-Stop engaged
  • No fuel/bad fuel
  • Low fluid levels/ contamination

Other considerations have to be made as well.

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Design to Maximize Product Availability

Discharged Batteries

  • Redundant starting batteries
  • Battery monitoring
  • Battery maintenance

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Design to Maximize Product Availability

Not in Auto/E-Stop engaged

  • Remote Annunciators
  • System Monitoring/Building management

systems

Poor fuel quality

  • Cleaning and polishing

§ Service § Installed system

  • Preventative Maintenance

§ Fuel sampling

Low fluid levels/filter contamination

  • Oil/Fuel systems where filters can be changed

during operation

  • On-site replacement filters and fluids
  • System monitoring
  • Fluid sampling
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Design for Maintenance & Repair: Other considerations

  • Is there adequate space to conduct

maintenance?

§ 3 feet on all sides § Enclosures: removable panels § Service elevators/Service doors

  • Does the site have overhead lift or

crane access?

  • Is there ease of access to connect

power modules if necessary?

§ Staging area § Electrical connections

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Design for Temporary Generators

  • Rental / Load Bank Planning

§ Facility quick connect for rental generators and load banks § Staging area § Emergency rental agreement § Connection Boxes

  • NEC 700.3.F
  • Load bank cabinet versus Generator

Dock

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Being Ready for the Storm

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What is the Duration of an Outage?

  • Outages can last from minutes to weeks

§ Power to site § Ability to service site

  • Hurricane Ike: Sept 13, 2008

§ 1 million outages in Texas one week after landfall § power fully restored on October 6*

  • Hurricane Sandy: Oct 29, 2012

§ 8.5 million outages at peak § Power fully restored on November 19*

  • Ice storms/Blizzards/Earthquakes

*US Department of Energy Office of Electricity Delivery & Energy Reliability

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Issues During Extended Outages

Fuel

  • Sites ran out of fuel
  • Contamination/Filters

Overheating

  • Plugged radiators - debris
  • Low coolant level

System lubrication

  • Oil filters clogged/need changing
  • Lube oil – makeup oil or oil changes

Lack of maintenance and testing

  • Generator end faults
  • Cracked hoses/belts

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General Maintenance Considerations

  • Before startup and during commissioning
  • Preventative maintenance
  • Monitoring, load testing, and records
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General Maintenance: Start Up

Before applying battery and shore power voltage to the generator set:

  • Inspect generator for debris, foreign objects, loose connections,

chafing, etc.

  • Check for proper grounding
  • Alignment, insulation test, winding resistance
  • Coordination of generator control and protective settings

During commissioning

  • Full system check and Inspection points (refer to O&MM)
  • Make adjustments as necessary

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General Maintenance: Preventative

  • Maintenance schedules depend on

product application

  • Standby generators: based off

calendar time

  • Prime/Continuous generators: based
  • ff service hours
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Generator Maintenance: Monitoring

Caterpillar recommends testing and sampling of oil, coolant, and the generator end as a part of standard maintenance

  • Trending data over time helps to

understand the health of the generator set

§ Focus on changes occurring over time § Better view of genset health then a single data point

  • Scheduled repairs instead of unplanned

downtime!

  • Sampling/testing looks for:

§ Generator End: shorts, insulation issues § Engine Oil: wear metals, TAN/TBN § Engine Coolant: oil, contaminants

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General Maintenance: Load Testing

Caterpillar recommends, and NFPA 110 (2016) requires, monthly and annual load testing

  • For EPS systems, minimum of 30% nameplate (or manufacturer recommendation) for at

least 30 minutes monthly, can be done with supplemental or site loads.

  • EPS installations that cannot meet this:

§ Exercised monthly with available load § Annually exercised with supplemental loads § 50% of nameplate for 30 continuous minutes § 75% of nameplate for 60 continuous minutes § 90 continuous minute test

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General Maintenance: Loading

Engines are designed to be run loaded

  • Minimum of 15% load suggested at all

times

  • Light or no load operation can lead to wet

stacking.

  • If extended light loaded during operation
  • ccurs, objectionable effect of wet

stacking can be avoided by loading the engine.

  • Recommendation is at least 30% load for

10 minutes every four hours of light load

  • peration.

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General Maintenance: Records and Testing

NFPA 110 (2016) requires record keeping and testing after operational tests, exercise repairs, and modifications to the EPS system

§ For maintenance reporting, include items needing attention and corrective action taken § Identification of servicing personnel § Can be made available to the AHJ upon request

  • After repairs made: testing completed for duration recommended by manufacturer

§ Initiated by ATS, and includes distribution breakers § 30 minutes under operating temperature if no recommendation by manufacturer

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General Maintenance: Ultra Low Sulfur Diesel

All diesel engines in the US now run off Ultra Low Sulfur Diesel (ULSD) fuel, which is 15 ppm sulfur.

  • Driven by emissions requirements, cleaner

burning and lower emissions than Low Sulfur Diesel (LSD), which was 500 ppm.

  • Multiple differences with ULSD fuel

§ Less stable and lower lubricity § Greater affinity to moisture and microbial growth

  • Shelf life limited: 6 to 12 months depending on

exposure to heat, temperature fluctuation, and moisture

  • USLD needs to be maintained

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Design to Help Manage Disasters

Maintenance and Testing

  • Preventative Maintenance reduces potential for unplanned shut down when emergency

power is needed, but needs to be done correctly

§ Local Dealer/Distributor must be able to perform factory warranty and be factory trained. § Service should be conducted per manufacturers guidelines

  • In the event of a outage

§ How many trained service personnel does the Dealer/Distributer have? § How close are they to site? Could they get there in the event of a disaster? § How large is the rental fleet the Dealer/Distributor has access to?

  • NFPA 110 (2016) requires AHJs to ask for proof of competency training

Sample Specifications: All repairs will be performed by factory trained dealer service personnel, and allows for repairer travel and mileage for all repairs up to 8 hours and 320 miles per incident. Equipment supplier shall have a minimum of 50 rental units to help increase availability. Confirmation of warranty compliance and rental inventory must be supplied on company letterhead with bid package. Bid must include Customer Service Agreement (CSA) for maintenance for 4 years after delivery, and include quarterly inspections and sampling per manufacturers guidelines.

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Design to Help Manage Disasters

Extended Service Coverage

  • Additional factory coverage from defects in workmanship or material
  • Caterpillar Platinum/Platinum Plus ESC

§ Added support in the event of emergency: crane, emergency ship, etc § Include rental generator coverage

  • Up to 10 years coverage for a new installation
  • Covered repairs can be done by any authorized dealer

Sample Specification: Extended Service Coverage shall be provided for a period of five (5) years, and shall include no deductible. The Extended Service Coverage provides for a rental power unit due to unscheduled failures causing unexpected downtime to the customer in excess of 48 hours from the time of diagnoses.

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Maintenance During an Extended Outage

  • Many sites plan for 24, 48, or 72

hours without normal power, but don’t make considerations about maintenance

  • How long does a generator have to

run during an extended outage before additional maintenance considerations have to be made?

250 hours = 10.4 days

*SEBU8479-01: Standby MIS for 3516C Generator Set

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Being Ready: What to Know and Have

Know How To:

  • Check oil on a running engine
  • Track engine temperature – look for air restrictions, quick start guide

control panel

  • Know how to read the fault codes
  • Parallel the system – have your staff practice

Parts Stocking

  • If you have 8-10 generators, you may want to have an extra battery

charger, battery testing equipment, battery load tester. 12VDC verse 24VDC systems.

  • Owner’s manual
  • Filters – Air/Fuel/Oil
  • Belts and Hoses
  • Coolant
  • Lube Oil – makeup and scheduled maintenance

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Topics Summary

  • Ratings and Usage

§ ISO 8528 § Caterpillar § EPA

  • Design for Emergency Preparedness

§ Facility design § The most common issues § Designing for maintenance

  • Being Ready for the Storm

§ Extended outages § Maintenance considerations § What to know and have

QUESTIONS?