Está en la página 1de 56

UNDERSTANDING

GENERATOR SET
RATING DEFINITIONS

Nick Paolo,
Regional Sales Engineer
MTU Onsite Energy
AGENDA

01. ISO Standard


02. Manufacturer Allowances
03. Exhaust Emissions
04. Specific Industry Ratings
05. Conclusion
01 ISO STANDARD

What does the ISO-8528-1 standard define?


ISO STANDARD
8528-1 INTRODUCTION

Where do our ratings come from?

8528-1: Applications, Ratings, &


Performance
8528-2: Engines
8528-3: AC generators for gensets
8528-4: Control gear & Switchgear
8528-5: Generating Sets
8528-6: Test Methods
8528-7: Technical Declarations for Specifications and
Design
8528-9: Measurement and Evaluations of Mechanical
Vibrations
8528-10: Measurement of Airborne Noise
8528-12: Emergency Power Supply to Safety Services
ISO STANDARD
8528-1 RATINGS

What ratings does ISO-8528-1 define?


Four types of ratings

1. Emergency Standby Power (ESP)

2. Prime Power (PRP)

3. Limited-Time Running Power (LTP)

4. Continuous Power (COP)


ISO STANDARD
CRITERIA # 1: ANNUAL RUN-TIME

Emergency Prime Power Limited-Time Continuous


Rating Type Standby Power (PRP) running Power Power
(ESP) (LTP) (COP)
Expected
Annual Run- 200 hours Unlimited 500 hours Unlimited
time

The expected annual run-time criteria establishes the annual hourly


usage expectation
ISO STANDARD
CRITERIA # 2: LOAD VARIABILITY

Emergency Prime Power Limited-Time Continuous


Rating Type Standby Power (PRP) running Power Power
(ESP) (LTP) (COP)
Expected
Annual Run- 200 hours Unlimited 500 hours Unlimited
time
Load Variability Variable Variable Undefined Constant
Variable Load Example Constant Load Example

The load variability criteria determines the load profile expectation


ISO STANDARD
CRITERIA #3: LOAD FACTOR

Emergency Prime Power Limited-Time Continuous


Rating Type Standby Power (PRP) running Power Power
(ESP) (LTP) (COP)
Expected
Annual Run- 200 hours Unlimited 500 hours Unlimited
time
Load Variability Variable Variable Undefined Constant
Average Load
70% 70% 100% 100%
Factor

The load factor criteria determines the expected average load over
any 24 hour operating period
ISO STANDARD Reference
LOAD FACTOR EXAMPLE Material

Power Time kW / 1000kW PRP rated unit


Output (hours) hrs
(kW)
1000 0.0 0 24 hour load profile shown
700 12.5 8750
650 8 5200 15,600 kW / hrs. accumulated
500 3.0 1500
300 0.5 150 Average 15,600 kW * hrs.
= = 650 kW
Totals 24 15,600 Load 24 hrs.

650 kW
Average Load Factor = = 65%
1000 kW
02 MANUFACTURER ALLOWANCES

How do manufacturers differ from each other?


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
MANUFACTURER ALLOWANCES
NET POWER vs. GROSS POWER EXAMPLE

Gross Power Output with electronically powered cooling fans


MANUFACTURER ALLOWANCES
NET POWER vs. GROSS POWER EXAMPLE

Net Power Output with electronically powered cooling fans


MANUFACTURER ALLOWANCES
NET POWER vs. GROSS POWER EXAMPLE

Net Power Output with belt driven cooling fans


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
MANUFACTURER ALLOWANCES
OVERLOAD CAPABILITY

What is overload?

Overload in the power generation


100%
industry is defined as additional
80%
power available for a short amount
% Load

60% of time
40%

20%
Commonly offered as 110% of the
0%
0 1 2 3 4 5 6 7 8 9 10 11 12 PRP rating
Hours

Typically utilized for load fluctuations


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
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
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
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
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
MANUFACTURER ALLOWANCES
LOAD FACTOR REAL WORLD ADVANTAGE

Scenario #1 Scenario #2 Scenario #3


Peak Power 525kW Peak Power 375kW Peak Power 275kW
Running Power 275kW Running Power 275kW Running Power 275kW
Load Factor 50% Load Factor 69% Load Factor 79%
Genset Size 550kW Genset Size 400kW Genset Size 350kW
MANUFACTURER ALLOWANCES
LOAD FACTOR REAL WORLD ADVANTAGE
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-8528-1 Minimum 70% 70% 100%
MANUFACTURER ALLOWANCES
MAXIMUM ANNUAL ESP RUN-TIME

No limit defined by ISO-8528-1 for


Does my genset Emergency Standby Power
have an annual
run-time limit? 200 hour annual recommendation

Some genset manufacturers give a


50-200 hour annual limit

MTU OE gensets have a 500 hour


annual recommendation
With no annual limit
Just follow the standard
maintenance program
MANUFACTURER ALLOWANCES
TIME BEFORE OVERHAUL (TBO)

No TBO defined by ISO-8528-1 for any


rating
Rating Hours

ESP 6000 Some manufacturers do not publish a


defined maintenance schedule with time
10,000- before overhaul clearly shown
PRP
15,000
Without TBO defined, products, quality,
COP 21,000 and ratings cannot be compared

MTU OE engines were initially designed


with defined TBO requirements
03 EXHAUST EMISSIONS

How do exhaust emissions impact the


generator set rating?
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


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


EXHAUST EMISSIONS
IMPACT TO GENSET RATINGS

Genset Rating EPA Classification


Exhaust emission requirements are
commonly thought to be officially related
Emergency to the genset ratings
Emergency Engines
Standby

Not true!

Non-Emergency Genset ratings are based on


Prime Power
Engines ISO-8528-1 & the genset
manufacturer's guidelines

Ratings & EPA emission class can be cross-applied


EXHAUST EMISSIONS
EMERGENCY REQUIREMENTS

Stationary Emergency
EMERGENCY DIESEL ENGINES
Category

Current requirements
breakdown into three Tiers

<50hp Engines : Tier 4

50-750hp: Engines: Tier 3

>750hp Engines: Tier 2


EXHAUST EMISSIONS
NON-EMERGENCY REQUIREMENTS

NON-EMERGENCY DIESEL ENGINES Stationary Non-


Emergency
Category

Tier 4
EXHAUST EMISSIONS
MOBILE REQUIREMENTS

Mobile Classification
NON-ROAD MOBILE DIESEL ENGINES

Current
requirements
All Tier 4
EXHAUST EMISSIONS
MOBILE REQUIREMENTS

Mobile Classification
NON-ROAD MOBILE DIESEL ENGINES
(continued)

TPEM or
mobile flexing
allows previous
certified Tier
EXHAUST EMISSIONS
FEDERAL CATEGORY EXCEPTIONS
Stationary
Class Emergency Non- Non-Road
Emergency Mobile Machinery

General When normal source Unlimited use in


Unlimited
Usage (utility) is not available mobile applications
Must move facilities
once per year to be
considered mobile
Exceptions 100 hours maint. & testing Requires
& Notes inducement** 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
EXHAUST EMISSIONS
NON-EMERGENCY DECISION

Should I buy just what I need?


Why does a customer want a Tier 4?
(Tier 2)

1. Participate in utility programs


Or should I spend more for a
Tier 4 certified genset
>50 hours per year (**currently being
so I can do utility programs? reviewed by EPA)

2. Run where no utility power


exists

3. Party influenced specification


to require Tier 4 (even though
not required)
EXHAUST EMISSIONS
NON-EMERGENCY DECISION

Should I buy just what I need?


What else could the customer do
(Tier 2)
with a certified Tier 4 product?

Or should I spend more for a


Tier 4 certified genset
1. Comply to local requirements
so I can do utility programs? Certification may
(if aligned) not be required!

2. Meet Best Available Control


Technology (BACT) requirements
Certification not
required!

3. Promote a green reputation


Certification not
required!
EXHAUST EMISSIONS
NON-EMERGENCY DECISION

Should I buy just what I need?


Why might a customer not want a
(Tier 2)
certified Tier 4 product?

Or should I spend more for a


Tier 4 certified genset
1. Price
so I can do utility programs?
Competitor market price
levels 50-70% above Tier 2

2. Inducement Concerns
EPA required shut-downs
add risk to mission critical
applications
EXHAUST EMISSIONS
NON-EMERGENCY DECISION

ESP Prime Power /


ESP
w/Utility Program Continuous Power

T4 Certification yes
Specified?
yes
Payback good?
no How would a
no
Want a green
reputation?
yes
customer make
no
this decision?
Local Emission yes Certified best yes
solution?
Requirements?

no
no
Tier 2 +
Tier 2 Tier 4 Certified
After-Treatment
EXHAUST EMISSIONS
REGIONAL REQUIREMENTS

Various regional requirements apply

Can be defined as:

1. State Agencies (DoE)


2. Regional Bureaus
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
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)
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
EXHAUST EMISSIONS
FACILITY LIMITS

Facility Limits (continued)

Twenty-eight 16V4000G83Ls
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
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
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.

SIPs 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)
EXHAUST EMISSIONS
FACILITY LIMITS

Facility Limits (continued)

Twenty-eight 16V4000G83Ls 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
EXHAUST EMISSIONS
SUMMARY

Exhaust emissions do not follow ISO-8528-1 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
04 SPECIFIC INDUSTRY RATINGS

What are some examples of rating requests


that do not fit into ISO standard definitions?
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
SPECIFIC INDUSTRY RATINGS
UPTIME INSTITUTE TIER CLASSIFICATION

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

ISO 8528-1 Ratings Uptime Institute


Requirements
Rating Emergency Prime Limited-Time Continuous
Type Standby Power running Power
Tier I & II Tier III & IV
Power Power
(ESP) (PRP) (LTP) (COP)

Expected
200
Annual 200 hours Unlimited 500 hours Unlimited Unlimited
hours
Run-time

Load
Variable Variable Undefined Constant Variable Variable
Variability

Average
Load 70% 70% 100% 100% Undefined 100%
Factor

No reliable
Back-up Grid Power Back-up Back-up
Usage utility
Power Programs Stations Power Power
applications
05 CONCLUSION

How do all these factors impact one another?


CONCLUSION
THE BALANCING ACT

Specific Industry Manufacturer


Ratings Allowances

Genset Purchaser Customers

ISO-8528-1 EPA Exhaust


Standard Emissions

The key to supporting the customer is an understanding of all factors!


test
ANY QUESTIONS?

THANK YOU
FOR YOUR ATTENTION

También podría gustarte