Installation Audits - Commissioning Gensets

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EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007

Installation Audits &Commissioning Gensets

Field Recommendations


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COMMISSIONING OBJECTIVES

Insure proper installation of

equipment

Engine/driven equipment

Peripheral supportequipment

Controls

Coordinate various disciplines

Contractors

Supplier reps

Electrical

Mechanical

Develop standardized

documentation and reporting

Insure contractual obligations

are met

Follow up on non

conformance issues

Complete performancetesting as required

Reduce warranty costs,eliminate rework

Assure customersatisfaction

Provide training on product andcross training

Manage all aspects ofcommissioning process

(including scheduling/invoicing)


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Successful commissioning starts in the office

Know the Package

Obtain TMI data far major

components, includingperformance specs

Know the scope of project supply

Systems Evaluation

Air Intake and Ventilation System

Cooling System

Starting System Exhaust and Crankcase

Ventilation System

Fuel and Lubrication System

Mounting and Alignment

Generator Safety, including Serviceability

Monitoring System

Tooling

Genset specific, plus basic

Diagnostic

Literature Operation and MaintenanceManual

Specifications, SystemsOperation/Testing andAdjusting, Disassembly andAssembly, Schematic,

Troubleshooting

Any relevant SpecialInstructions

Installation and Initial

Start-up Procedure

Alignment

Check SIS for latest EN, TIBand/or Service letters


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Use A&I guides for reference

- Electric Power A&I, all included LEBE1924 - Exhaust Systems LEBW4970

- Air Intake Systems LEBW4969 - Gas Engine Emissions LEBW4984

- Alignment LEBW4975 - Gaseous Fuel Systems LEBW5336

- Control Systems - Diesel LEBW4981 - Gaseous Fuels LEBW4977

- Control Systems & Ignition - Gas LEBW4982- Generation Systems (includes

packaging info)LEBE5293

- Cooling Systems LEBW4978 - Governors - Gas & Diesel LEBW4979

- Crankcase Ventilation LEBW4958 - Lubrication Systems LEBW4957

- Diesel Fuels & Fuel Systems LEBW4976 - Mounting LEBW4974

- EMCP3 LEBE5255 - Noise LEBW4973

- Engine Room DesignConsiderations

LEBW4994 - Piping System BasicInformation

LEBW4991

- Engine Room Ventilation LEBW4971 - Starting Systems LEBW4980

- EPG Intro, Applications & Engine

Selection (Sizing)LEBE5294 - Vibration LEBW4972


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When to Use Multiple Engines

N + 1 Requirements

Redundancy

Service Flexibility Distribution Voltage/Current Limit

Lowest InstalledCombination

Significant LoadVariation atSpecific Times

High Starting/Low

Rated PowerRequirements


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Paralleling Operation

Isoc - Load Share (2301ALoad Share)

Equal Share at Isoc Speed

0-100% Operating Range Isoc- Droop

1 Base Load at Isoc

1 Swing Load w/ Droop

0-100% Operating RangePossible; typically requiresoutside control

Droop - Droop

Equal Share at DroopSpeed

0-100% Operating Range

Synchronization

Paralleling Unit To BusRequires Same Frequency,

Phase Rotation, and InPhase

Automatic Devices Perform

Function

Manual

Synchronizing Lights

Synchronizing Meters Remember about kVAR

sharing


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Load Control

Load Prioritization - ATS Control System

Load Acceptance Order

Load Shedding Order

Unit Starting Order

Unit Shut Down Order

Synchronization Order


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Generator Selection Considerations

Load Profile

Load List = Load Profile?

Sized for Worst Case?

Linear Loads - Motors, Lighting

Non-linear Loads - Up to 60% of

Rating, Remainder 40% Linear -without De-rate

Harmonic Content

Generator Heating

Generator spec

Generator Temperature Rise

Generator Pitch

Insulation System

Voltage - Numberof Leads

Generator vs Engine Size

KVA vs KW Requirements

bkW = (ekW / Gen Eff. ) + FanDemand

SKVA Voltage Dip - Generator

Transient Load Changes

Frequency Dip - Engine

Voltage Dip - Generator


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Load Balance

3 Phase Generator

3 Phase Balance Loads

L - L Loads L - N Loads

Balance Phases with

Similar Loads

Size is Determined by Highest Phase Current and % Unbalance


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0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016 0.018-1

-0.5

0

0.5

1

Harmonics

The third harmonic gets the most attention

because it is the closest harmonic and is alsosynchronized with H1 in a three phasemachine.

When a three phase alternator is directlygrounded there is no impedance torestrict the circulation of currents.

By reducing the pole pitch the third

harmonic can be eliminated.

Pitch = (throw-1) x #poles

# of slots


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Load Steps

Load Stepping - Prioritization

Reduces Transients

Load Shedding Scheme

Load Step Type

Block Load

Motor Load

Transformer

Multi-Unit Timing

First to Rated First Load Step

Parallel

Second Load Step

First to Rated

Parallel

One Large Load Step

Transient Response Factors

Load Step Type

Genset Package

Configuration Generator Configuration

System Interaction


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Caterpillar EP SpecSizer, LERX5475


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Load Step Type

Block Load Instantaneous load

acceptance/rejection

Typical 1.0 pf or 0.8 pf

Actual load conditions typically do

not represent pure block loads

Motor loads Dependent on motor starting

technique

Typical high SKVA requirement andlow HP requirement at time = zero

Transformers

High Inrush Current, Are Not Include in Sizing Engine

Magnetizing Current - Typical Less Than 20 Cycles


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Genset Package Configuration

Engine Mounted Radiator Fan Demand

Transient Response Dependent on Acceleration bkW

Fan Demand Reduces Acceleration bkW

Added System Inertia

Air System Design

Change in Boost Pressure

Small / Low Inertia Turbochargers - Best

Large / High Inertia Turbochargers - Worst

System Trade - Off

Fuel Consumption vs. Response


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BMEP Load Steps

Load acceptance capability

dependent on BMEP Load Step

ISO 8528-5, rated BMEP determines

% Block Load requirement

Higher ratings reduce transientperformance

The higher the engine BMEP andefficiency the worse its ability topickup load

At best gas engines are half as goodas diesel. Lean burn, low gaspressure are worst

EDS 74.2 Block LoadingTransient

Different Transient Classes, Gas Engine - G1

Diesel Engine - G2

VoltageFrequencyISO 8528-5

-20%-25%-10%

-20%

-15%

-25%

Stepped load increase

Gas engines

+25%+35%+12%+18%100% load decrease

5

Class 2

61010Recovery time (sec)

Class 2Class 1Class 1

VoltageFrequencyISO 8528-5

-20%-25%-10%

-20%

-15%

-25%

Stepped load increase

Gas engines

+25%+35%+12%+18%100% load decrease

5

Class 2

61010Recovery time (sec)

Class 2Class 1Class 1


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Generator Configuration & Transient response

Volts / Hertz% Regulated Voltage Dip = Frequency Dip

Example:

10% Freq. Dip = 10% Voltage Dip

= .90 Voltage= .81 Power

Tight Voltage

Longer Response Time

2 Volts / Hertz2x% Regulated Voltage Dip = %Frequency Dip

Example:

10% Freq. Dip = 20% Voltage Dip

= .80 Voltage= .64 Power

More Voltage Dip

Faster Response Time


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Enclosures Rotating Electrical Machines

Most Common International Protection Codes

IP21

IP22 IP23

IP44

IP54

IP55 IP56


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Selecting the correct enclosure

Clean and well ventilated machine room

IP 21-23 is perfectly suited

90% of all generators installed are IP21-23

Humid and salt ladenenvironment

Evaluate the quality of

the filtration andventilation system of thepower house. IP23 could

be appropriate.

Space heater ismandatory.

Check load schedule, anunder loaded machine isa risk.


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Humid an Salt laden environment

A filtered unit will eliminate solid contaminants. IP44S.


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Totally Enclosed Fan Cooled (CACA)

- IP 54 & IP 55

- Fan drivensecondary air circuit.

- Power ratings from500 ekW to 15 000ekW

- Offshore-Petroleumapplications


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Totally Enclosed Water Cooled (CACW)

- IP 54 & IP 55

- Single or DoubleTube Construction

- Primarily forMarineApplications


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Commissioning Field Check Lists

Engine Start-up checklist:

Governor & Fuel systeminformation

Cooling system:

Lubrication system:

Exhaust system

Mounting

Vibration levels

Batteries

Jacket water heaters

Crankcase ventilation Protection system accuracy &

functional tests.

ECM Configuration settings

ECM Monitoring settings

Genset Start-up Check list

EMCP Configuration settings VR Configuration settings

Rating information

Generator name plate information

Electrical

Megohmmeter test

Grounding, cabling

Mechanical

Bearings, air gaps

Switch gear/parallel operation Enclosure, Utily Grade, etc.

Application & load information

Customer Data

Engine data

Generator data

Customer orientation

Full load data

Statement of completion

Environment, Ambient conditions

Safety

Serviceability


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Examples

Room Ventilation

Engine Air Intake

Radiator Mounting


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Examples

Cables routing,

Generator ventilation,

Site safety


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Examples

Cooling pump side load


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Examples

Exhaust routing


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Examples

Exhaust bellow

misalignment


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Examples

Air Intake

misalignment


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Examples

JW heater

pump misinstall


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Examples

Batteries cables Overloading on CB bars


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Examples

By pass line

connection


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Examples

Mounting isolators not set


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Running withopen doors

will overheat

the generator

due to air

recirculation

Installation Audits - Commissioning Gensets

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