Cummins Power Generation Power Training M d l 7 P T i i Module Generator Sizing

Bob Patrick October 2008

Sizing the Genset for Motors.

Two Factors must have 1. 1 Available additional engine torque to support both the existing load plus accelerate the motor up to full speed within the spec limits. p p
(Acceleration Torque = advised Nm x rpm x 2/60 = watts)

2. Alternator capability t overcome th motor i 2 Alt t bilit to the t inrush h and sustain the voltage within the spec limits.

DOL Starters
600 PERCEN TORQUE, POWER, CURR NT P RENT

Current Power Factor

PO OWER FACTOR (LAGGING) R 1.0

Direct On-Line (DOL) Start High Locked Rotor Current (kVA) g ( ) Shown for 100% Rated Voltage Starting PF 0.2 to 0.4 for 3 Motors Higher Starting Requirements g g q

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Motor Torque
0 20 40 60 80 PERCENT MOTOR RATED SPEED

0.2

Load Torque
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Star-delta Starting
Typical kW demand of motor

Reduced Starting Impact Watch out for the transition (kVA) Potential start failure if alternator ca ot susta cannot sustain voltage in t a s t o o tage transition.

Typical kVA demand of motor

Soft Starting
Motor Response for Soft Starter

Regenerative Load
Reverse power needs to be considered.

Regenerative Load
Stage 1:1: Genset Supplies Site Loads Stage 2:Lift Motor Produces M t P d Reverse Power 200kW 100kW Load Bank Removes Risk of Reverse Power

Transients
Step Loading the Generator
Apply Load in Increments Apply Large Motor Loads First Limit Voltage and Frequency dip Ultimately reduce genset size

Step Starting Sequence

ISO 8528 - 5
ISO 8528 specifies d i and performance ifi design d f criteria of Reciprocating Internal Combustion (RIC) engine and an Alternating Current (AC) generator when operating as a unit.

Voltage Transients.
ISO 8528-5 Transient Requirements

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Frequency Transients.
ISO 8528-5 Transient Requirements

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Transients.
ISO 8528-5 Performance Classes
Class G1 This applies to generating set applications where the connected loads are such that only basic parameters of voltage and frequency need to be specified. specified EXAMPLE General-purpose applications (lighting and other simple electrical loads) loads).

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Transients.
ISO 8528-5 Performance Classes
Class G2 This applies to generating set applications where its voltage characteristics are very similar to those for the commercial public utility electrical power system with which it operates. operates When load changes occur, there may be temporary but acceptable deviations of voltage and frequency. EXAMPLE Lighting systems, pumps, fans and hoists.

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Transients.
ISO 8528-5 Performance Classes

An example of Class G2 voltage and frequency requirements: Transient Frequency Dip </= 10% Frequency Recovery Time </= 5 Secs Steady State Voltage Deviation </= +/- 2.5% Transient Voltage Dip </= 20% Voltage Recovery Time </= 6 Secs

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Transients.
ISO 8528-5 Performance Classes
Class G3 This applies to applications where the connected equipment makes severe demands on the stability and level of the frequency, frequency voltage and waveform characteristics of the electrical power supplied by the generating set. EXAMPLE Telecommunications and thyristor-controlled loads. It should be remembered that both rectifier and thyristor-controlled loads may need special consideration with respect to their effect on generator-voltage waveform. p g g

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Transients.
ISO 8528-5 Performance Classes
Class G4 This applies to applications where the demands made on the stability and level of the frequency, voltage and waveform characteristics of the electrical power supplied by the generating set are exceptionally severe. EXAMPLE Data-processing equipment or computer systems. systems

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Voltage Transients.
Locked Rotor Curve
Locked R t C L k d Rotor Curve f for 1400kVA alternator g Used to aid sizing Approx 14% dip at 1000kVA (depends on voltage) Allow 0.5% Volts Dip for every 1% Freq Dip

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Sizing.
Can be very simple a simple addition with diversity, etc., or... y, , More complex when considering difficult loads and load step sequencing.

Difficult loads: Electric motors, UPS, Lighting, Medical equipment

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Power Suite
Cummins Power Suite.lnk

Cummins Sizing Tool Gensize (To calculate your generator requirements) Has a database using CPG product test data

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Power Suite Demonstration

Any Questions before we move on

Bob Patrick October 2008

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GenSize Update PSG/Proposals T PSG/P l Team

Part IIb Training.

Bob Patrick October O t b 2008

Installing Power Suite Central Update

Install Power Suite 4.0 From CD

Auto update from central database,

http://www.cumminspower.com/na/technical/powersuite/webcenter/ Central database replaces original database
Power Suite Central Library y & Update CD
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PC running Power Suite V4 0 V4.0

Updates Via Internet Auto-updates from central database, p ,

http://www.cumminspower.com/na/technical/powersuite/webcenter/

Select: Updated files for Europe, Middle East and Africa.

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Updates Via Internet Auto Updates GenSize for MSWindows

Cummins Power Suite

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Opening Screen: Create New Project

With Project highlighted Click on Open

The opening screen allows import previous or create new project

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Gensize M i S G i Main Screen: S tti Setting U Up Project Parameters

Current Project Parameters

Expand New Project in left column

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Gensize Main Screen: Setting Up Project Parameters

Shows current loads and steps available

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Gensize M i S G i Main Screen: S tti Setting U Up Project Parameters

Click on Edit Edit Project

Once expanded right click on project and select Edit Project

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Gensize Main Screen: Setting Up Project Parameters

Select Parameters tab

Project parameters box will appear

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Gensize Main Screen: Setting Up Project Parameters

Current Project Parameters

Set the required project parameters

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Gensize Main Screen: Setting Up Project Parameters

Once complete, click OK to continue

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Gensize Main Screen: Creating Loads

Add lighting load by clicking on th b lb the bulb

Select load type from toolbar

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Gensize Main Screen: Creating Loads

Enter 100kW lighting load g g Click Next for more options Example shows 3 phase 100 kW fluorescent lights
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Gensize Main Screen: Creating Loads

Shows requirements for 100kW light load Click Finish to complete load

Review Load Requirements

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Gensize Main Screen: Creating Loads

Light load now created Whilst highlighted, the light load parameters appear t

Lighting load appears in left pane

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Gensize Main Screen: Creating Loads

Light Load can now be dragged in to step 1 gg p

Apply load to desired load step

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Gensize Main Screen: Creating Loads

Step 1 showing Light Load

Project can now be sized by clicking the Size Project j button

Minimum Requirements For Sizing Project

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Gensize Main Screen: Sizing Project

Gensize calculating project requirements to find match

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Reports: Recommended Generator Model

Recommended Model Project parameters Performance Vs Requirements

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Reports: Recommended G R t R d d Generator t Model

Recommended Model Performance Vs Requirements

Load L d parameters t

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Reports: Recommended G R t R d d Generator t Model

Recommended Model Performance Vs Requirements

Generator Config G t C fi

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Reports: Recommended G R t R d d Generator t Model

Click for full genset report

Changing the report type

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Reports: Recommended G R t R d d Generator t Model

Printable Genset Report

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Reports: Recommended G R t R d d Generator t Model

Close Report

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Reports: Recommended G R t R d d Generator t Model

Switch to Table View

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Reports: Recommended Generator Model

Table View Used For Cross Referencing Models

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Reports: Recommended G R t R d d Generator t Model

Switch to library y
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Central Library CD

Exit Library to return Gensize

Shows recommended model and technical data

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Gensize Main Screen: Adding Load Steps

To add single load step click here

Extra load steps can be added at any time

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Gensize Main Screen: Adding Load Steps p

Second Load Step p

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Gensize M i S G i Main Screen: Addi Adding L d Load Steps

You can define the number of steps required

There are 2 ways to add extra load steps

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Gensize Main Screen: Adding Load Steps

Specify number of required load steps

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Gensize Main Screen: Adding Load Steps

New loads can then be added to each step

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Gensize Main Screen: Adding Load Steps

Here we will add 400HP motor

Click Next for Cli k N t f more options New loads can then be added to each step
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Gensize Main Screen: Adding Load Steps

Click Finish

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Gensize Main S G Screen: Adding Load Steps

New motor load added Motor load dragged to gg Step 2

Adding the new load to Step 2

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Gensize Main S G Screen: Adding Load Steps

Sized generator with 2 load steps

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Gensize M i S G i Main Screen: Ch Change Quantity

Quantities of each load can be changed

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Gensize Main Screen: Change Quantity

Quantity changes to 2 y g

Quantities of each load can be changed

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Gensize M i S G i Main Screen: S i Saving Projects

Project can be saved at any time using the File menu

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Gensize M i S G i Main Screen: S i Saving Projects

Directory File Name

Default projects directory

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Gensize Main Screen: Saving Projects

Check for confirmation before closing!

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Workshop
Lighting Loads General Loads UPS Loads Motor Loads Round-Up

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LIGHTING LOADS
Power input

Lighting requirement Type of load Requirement for generator

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LIGHTING LOADS

Power factor requirements

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GENERAL LOADS
Power inputs Power requirements Requirement for generator

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GENERAL LOADS

Both Start and run power factors must be entered

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UPS LOAD

UPS Output power UPS requirement UPS type

Requirement for generator

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UPS LOAD

UPS characteristics which are crittical. hi h i i l

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MOTOR LOADS

Motor shaft power Motor requirement Motor type

Requirement for generator

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MOTOR LOADS

Motor starting type

Motor starting characteristics Motor r nning running characteristics

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Thank you for your time

Any Questions

Bob Patrick October 2008

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