Installation Audits - Commissioning Gensets

Installation Audits & Commissioning Gensets Field Recommendations

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

COMMISSIONING OBJECTIVES •

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Insure proper installation of equipment • Engine/driven equipment • Peripheral support equipment • Controls Coordinate various disciplines • Contractors • Supplier reps • Electrical • Mechanical Develop standardized documentation and reporting

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Insure contractual obligations are met – Follow up on non conformance issues – Complete performance testing as required – Reduce warranty costs, eliminate rework – Assure customer satisfaction Provide training on product and cross training Manage all aspects of commissioning process (including scheduling/invoicing)

EAME/CIS TC Conference EP/Petroleum - Malaga, October 2007 2

Successful commissioning starts in the office • Know the Package – Obtain TMI data far major components, including performance 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 Maintenance Manual – Specifications, Systems Operation/Testing and Adjusting, Disassembly and Assembly, Schematic, Troubleshooting – Any relevant Special Instructions • Installation and Initial Start-up Procedure • Alignment – Check SIS for latest EN, TIB and/or Service letters


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 LEBE5293 packaging info)

- 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 Design Considerations

LEBW4994

- Piping System Basic Information

LEBW4991

- Engine Room Ventilation

LEBW4971

- Starting Systems

LEBW4980

- EPG Intro, Applications & Engine Selection (Sizing)

LEBE5294

- Vibration

LEBW4972


When to Use Multiple Engines • N + 1 Requirements – Redundancy – Service Flexibility • Distribution Voltage/Current Limit • Lowest Installed Combination • Significant Load Variation at Specific Times • High Starting/Low Rated Power Requirements


Paralleling Operation • Isoc - Load Share (2301A Load 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 Range Possible; typically requires outside control • Droop - Droop – Equal Share at Droop Speed – 0-100% Operating Range

• Synchronization – Paralleling Unit To Bus Requires Same Frequency, Phase Rotation, and In Phase – Automatic Devices Perform Function – Manual • Synchronizing Lights • Synchronizing Meters – Remember about kVAR sharing


Load Control • Load Prioritization - ATS Control System – Load Acceptance Order – Load Shedding Order – Unit Starting Order – Unit Shut Down Order – Synchronization Order


Generator Selection Considerations •

Load Profile – – – –

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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

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Generator vs Engine Size – KVA vs KW Requirements • bkW = (ekW / Gen Eff. ) + Fan Demand – SKVA Voltage Dip - Generator – Transient Load Changes • Frequency Dip - Engine • Voltage Dip - Generator

Generator spec – – – –

Generator Temperature Rise Generator Pitch Insulation System Voltage - Number of Leads


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


Harmonics •

The third harmonic gets the most attention because it is the closest harmonic and is also synchronized with H1 in a three phase machine. – When a three phase alternator is directly grounded there is no impedance to restrict the circulation of currents. – By reducing the pole pitch the third harmonic can be eliminated. 1

0.5

•Pitch = (throw-1) x #poles # of slots

0 -0.5 -1 0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

0.018


Load Steps •

Load Stepping - Prioritization – Reduces Transients – Load Shedding Scheme

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Load Step Type – Block Load – Motor Load – Transformer

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Transient Response Factors – Load Step Type – Genset Package Configuration – Generator Configuration – System Interaction

Multi-Unit Timing – First to Rated • First Load Step • Parallel • Second Load Step – First to Rated • Parallel • One Large Load Step


Caterpillar EP SpecSizer, LERX5475


Load Step Type Transformers • •

High Inrush Current, Are Not Include in Sizing Engine Magnetizing Current - Typical Less Than 20 Cycles

Block Load

Motor loads

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Instantaneous load acceptance/rejection – Typical 1.0 pf or 0.8 pf Actual load conditions typically do not represent pure block loads

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Dependent on motor starting technique Typical high SKVA requirement and low HP requirement at time = zero


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


BMEP Load Steps •

Load acceptance capability dependent on BMEP Load Step – ISO 8528-5, rated BMEP determines % Block Load requirement – Higher ratings reduce transient performance – The higher the engine BMEP and efficiency the worse its ability to pickup load – At best gas engines are half as good as diesel. Lean burn, low gas pressure are worst

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EDS 74.2 “Block Loading Transient” Different Transient Classes, – Gas Engine - G1 – Diesel Engine - G2

ISO 8528-5 Recovery time (sec)

Frequency Voltage Class 1 Class 2 Class 1 Class 2 10

Stepped load increase -15% Gas engines -25% 100% load decrease +18%

5

10

6

-10% -20% +12%

-25%

-20%

+35%

+25%


Generator Configuration & Transient response Volts / Hertz

2 Volts / Hertz

% Regulated Voltage Dip = Frequency Dip

2x% Regulated Voltage Dip = %Frequency Dip

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Example: – 10% Freq. Dip = 10% Voltage Dip = .90 Voltage = .81 Power Tight Voltage Longer Response Time

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Example: – 10% Freq. Dip = 20% Voltage Dip = .80 Voltage = .64 Power More Voltage Dip Faster Response Time


Ten Second Start Non-Paralleled Gensets •

Cranking Batteries need to be properly sized, cells in good condition, and fully charged – Short Battery Cables, may need Battery heaters

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Combustion Air must be minimum 21C – Warm Air Intake Until Engine is up to Rated Speed, louvers.

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Jacket Water Temp must be minimum 32C Jacket Water Heaters

• Good Fuel Supply… – Includes supply & return lines, Fuel heaters.

• Properly sized Generator rotating inertia • Generator Start Signal time delay minimized • Switchgear Breaker close time delay minimize


Enclosures Rotating Electrical Machines •

Most Common International Protection Codes – – – – – – –

IP21 IP22 IP23 IP44 IP54 IP55 IP56


Selecting the correct enclosure •

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Clean and well ventilated machine room • IP 21-23 is perfectly suited • 90% of all generators installed are IP21-23 Humid and salt laden environment • Evaluate the quality of the filtration and ventilation system of the power house. IP23 could be appropriate. • Space heater is mandatory. • Check load schedule, an under loaded machine is a risk.


Humid an Salt laden environment – A filtered unit will eliminate solid contaminants. IP44S.


Totally Enclosed Fan Cooled (CACA)

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IP 54 & IP 55

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Fan driven secondary air circuit.

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Power ratings from 500 ekW to 15 000 ekW

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Offshore-Petroleum applications


Totally Enclosed Water Cooled (CACW)

- IP 54 & IP 55 - Single or Double Tube Construction - Primarily for Marine Applications


Commissioning – Field Check Lists • • •

Customer Data Engine data Generator data •

• • •

Environment, Ambient conditions Safety Serviceability

Engine Start-up checklist: – Governor & Fuel system information – 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

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Customer orientation Full load data Statement of completion

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


Examples • Room Ventilation • Engine Air Intake • Radiator Mounting


Examples • Cables routing, • Generator ventilation, • Site safety


Examples

• Cooling pump side load


Examples

• Exhaust routing


Examples

• Exhaust bellow misalignment


Examples

• Air Intake misalignment


Examples

• JW heater pump misinstall


Examples • Batteries cables

• Overloading on CB bars


Examples

• By pass line connection


Examples • Mounting isolators not set


• Running with open doors will overheat the generator due to air recirculation


Installation Audits - Commissioning Gensets

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