RTG & VSG Presentation EGSA Conference Sept. 18, 2006 Alan - - PowerPoint PPT Presentation

RTG & VSG Presentation

EGSA Conference

• Sept. 18, 2006

Alan McDonnell Bill Young

Sales Manager President Youtility Inc. Industrial Power Systems Inc.

11 Executive Dr. Hudson, NH 03051 3010 Powers Ave. Jacksonville, FL 32259

INDUSTRIAL POWER SYSTEMS, INC

VSG – Fixed Speed Comparison

• The following slide shows a

comparison between the fixed speed power generation model and a variable speed industrial model CAT C32 ACERT,

• ne of their newest

electronic engines

• Both engines meet EPA

Tier 2 emissions

Total Fuel (lb-hr) Power (kWe) 1000 600 200 400 800 500 300 200 100 400

100

1800 RPM vs. 700-2100 RPM

100% 50% 110% 1000 600 200 400 800

100

Maximum Torque Mode Expected Maximum Efficiency Mode Output (kWe)

Fixed Speed Fuel Consumption

• vs. Variable Speed

Economical Applications of VSG

• The economics of adding the VSG system

will be better for applications with low average power demands

• Cranes that require full power for only

short periods of time while lifting are good candidates

• With a VSG installed, the engine will idle

most of the time, and increase in speed

• nly when needed

IPS and Youtility

• Have designed a system that can be

easily retro-fitted to existing RTG Cranes

• Several hundred existing cranes in service

globally

• Youtility supplies electronic equipment,

design responsibility and support to IPS

• IPS builds necessary electrical equipment,

installation and project management

Typical RTG (Rubber Tire Gantry)

Basic VSG Diagram

VSG Control AC Supply

Ultra

• cap

Variable Speed Generator Crane AC power feed

800VDC 400 - 720VDC 290VAC - 36Hz to 480VAC - 60Hz

Detailed VSG Diagram

Pre-Charge Contactor (+) (-)

Rectifier Boost Output AC Inverter Bypass / Isolation Contactors - Interlocked Energy Store / Release Chopper control

Generator 250kVA 200kW 480V 1800RPM

N 6.7L 153kW

Energy Storage

Variable DC Regulated 800VDC

Unique Features of Crane Electrical Power Requirements

• New Cranes use AC VFDs to power

motors, the major loads (90%)

• AC VFD consists of a DC rectifier feeding

DC power to an AC inverter

• Since the VSG also makes DC power, it

can be fed directly on a “common DC bus”

VSG with common DC bus

VSG Control AC VFDs AC Supply

Ultra

• cap

M M M

Variable Speed Generator

• aux. loads

800VDC 400 - 720VDC 480VAC - 60Hz 290VAC - 36Hz to 480VAC - 60Hz

Detailed crane DC bus unit

Pre-Charge Contactor (+) (-)

Rectifier Boost Output AC Inverter Bypass / Isolation Contactors - Interlocked Energy Store / Release Chopper control

Generator 250kVA 200kW 480V 1800RPM

N 6.7L 153kW

Energy Storage DC Bus power connection

Variable DC Regulated 800VDC

Energy Storage Advantages

• Engine produces poor step change power at low speeds
• Energy Storage can supply full rated power in less than
• 4mSec. With DC/DC boost circuit
• Energy Storage can reclaim energy that otherwise goes to

Dynamic Braking Resistors

• Energy Storage can “smooth” the power required from the

generator, less peak required…therefore smaller generator

• For high cyclic loads, we prefer Ultra-Capacitors over

batteries

A Maxwell brand Ultra-Capacitor

Energy Storage Calculations

• 48V x 144F each bank
• 16 banks in series = 768VDC x 9F
• Total energy = ½ * c * V 2 = 2.6MJ
• Useable energy = 0.7 x 2.5MJ = 1.75MJ
• Need 400kW (peak) – 150kW (engine) =

250kW x 7sec. = 1.75MJ

RTG Crane Expectations

• Overall Fuel Consumption reductions of 30% -

50%

• Total Emissions reductions of 70% - 90%
• Reduce 23L engine to 6.7L engine
• Reduce Idling Fuel Consumption from

20+ L/hr. to 2 L/hr.

• We predict all future cranes will be VSG in less

than 2 years, based on market competition

Other VSG Applications

• Most economical for variable load or less

than full load applications

• Grid Connect, Stand Alone or Parallel Unit

Operations

• Combined Heat-Power total efficiency for

part-load conditions is much improved

• High power quality requirement

applications

Other VSG System Features

• Transformerless output with full unbalanced load

capabilities

• Synchronous Generator with integral field control, no

need to use a different generator

• 96%+ pf. on generator, allows higher outputs with

full VA rating utilized

• Integrated Energy Storage allows full step load

changes in ¼ cycle, no freq. deviation

End of Presentation

• Bill Young

Industrial Power Systems, Inc.

• Alan McDonnell

Youtility Distributed Power Electronics