Generators and Emergency Preparedness Jess Treadway, Caterpillar - PDF document

10/8/19 Caterpillar: Confidential Green Generators and Emergency Preparedness Jess Treadway, Caterpillar Jonathan Rall, Ring Power Topics • Ratings and Usage § ISO 8528 § Caterpillar § EPA • Design for Emergency Preparedness § Facility design § The most common issues § Designing for maintenance • Being Ready for the Storm § Extended outages § Maintenance considerations § What to know and have 2 Electric Power Division Caterpillar: Confidential Green 1

10/8/19 Ratings and Usage 3 Electric Power Division Caterpillar: Confidential Green Why are Ratings Important? • Over aggressive use of ratings could result in accelerated wear and unplanned downtime • Over conservative use of ratings removes value, increases cost, can cause performance issues and potentially lead to maintenance issues. • Major Considerations § Number of expected run hours per year. § Average load versus Peak load § Ultimate Application: Is the generator set the normal source or emergency source? Is it normally paralleled with other sources? 4 Electric Power Division Caterpillar: Confidential Green 2

10/8/19 Ratings Confusion in Specifications Specification: Section 5.A “Generator shall be rated 2 MW Standby, 1825 kW prime” • Ratings designed to help drive understanding between users, engineers, and manufacturers • What is more important to the site? § Starting time and transient response? § Fuel consumption and time between overhauls? • Specifications such as this can drive unnecessary cost into projects Key: What is the application of the generator set 5 Electric Power Division Caterpillar: Confidential Green What is ISO8528? • International standard for diesel and gas generator sets • Intended to help understanding between manufacturer and customer • ISO 8528 defines four ratings § Continuous Power (COP) § Prime Power (PRP) § Limited-Time Running Power (LTP) § Emergency Standby Power (ESP) § Data Center Power (DCP) Should be considered as a minimum standard for manufacturers 6 Electric Power Division Caterpillar: Confidential Green 3

10/8/19 Continuous Power (COP) Definition: The maximum power which the generator set is capable of delivering continuously whilst supplying a constant electrical load when operated for an unlimited number of hours per year under the agreed operating conditions with the maintenance intervals and procedures being carried out as prescribed by the manufacturer. Power COP pow er (100%) COP Key Points • Unlimited Hours per year • Load 100% Nameplate • Constant Electrical Load Time stops for maintenance 7 Electric Power Division Caterpillar: Confidential Green Prime Power (PRP) Definition: The maximum power which the generator set is capable of delivering continuously whilst supplying a variable electrical load when operated for an unlimited number of hours per year under the agreed operating conditions with the maintenance intervals and procedures being carried out as prescribed by the manufacturer. The permissible average power output over 24hr of operation shall not exceed 70% of the PRP unless otherwise agreed by the engine manufacturer Power PRP Key Points PRP pow er (100%) P6 • Unlimited Hours per Year P3 Permissible average pow er P4 • Not to exceed 70% average P1 load in 24 hours P2 • Variable Electrical Load Actual average pow er P5 30% t1 t2 t3 t4 Stop t5 t6 Time 8 Electric Power Division Caterpillar: Confidential Green 4

10/8/19 Limited-Time Power (LTP) Definition: The maximum power available, under the agreed operating conditions, for which the generator set is capable of delivering for up to 500hr of operation per year with the maintenance intervals and procedures being carried out as prescribed by the manufactures Limited time running power at 100% is limited to a maximum of 500hrs per year Power LTP pow er (100%) LTP Key Points • Limited to 500 Hours per Year • Load 100% of Nameplate • Constant Electrical Load stop stop stop Time 9 Electric Power Division Caterpillar: Confidential Green Emergency Standby Power (ESP) Definition: The maximum power available during a variable electrical power sequence, under the stated operating conditions, for which a generating set is capable of delivering in the event of a utility power outage or under test conditions for up to 200hr of operation per year with the maintenance intervals and procedures being carried out as prescribed by the manufacturer The permissible average power output over 24hr of operation shall not exceed 70% of the ESP unless otherwise agreed by the RIC engine manufacturer Power ESP Key Points ESP pow er (100%) P5 • Limited to 200 Hours per P2 Permissible average pow er year P3 • Not to exceed 70% average P1 load in 24 hours • Variable Electrical Load Actual average pow er P4 30% Stop t1 t2 t3 Stop t4 t5 Stop Time 10 Electric Power Division Caterpillar: Confidential Green 5

10/8/19 Data Center Power (DCP) Released 2018 Definition: Data Center Power is the maximum power that a genset is capable of providing, at a variable or continuous load, for an unlimited number of hours. Depending on the site’s requirements & the availability of a reliable grid supply, it’s the responsibility of the genset manufacturer to define the level of power that the genset can supply to meet the requirement, including modification of hardware, software or maintenance schedule. Note: An engine-driven ac generator is a reliable power source for a data center & can also be used as back-up for a reliable grid. Prolonged paralleling to the grid is not permitted. DCP Key Points • Capable of providing power for unlimited hours • Manufacturer reasonability to define power level based off site requirements • Variable or Continuous Electrical Load 11 Electric Power Division Caterpillar: Confidential Green Cat Ratings versus ISO8528 Ratings Differences between ISO8528 Ratings and Cat Ratings • ISO8528 ratings: states average load factors and usage as hard limitations • Caterpillar ratings: average load factors and usage are not hard limitations, rather guidance. • Additional differences on certain specific ratings ISO8521 Rating Caterpillar Rating Continuous (COP) Continuous Rating Prime Power (PRP) Prime Power (Exceeds PRP) Limited Time Running (LTP) Load Management (Exceeds LTP) Standby (Exceeds ESP) Emergency Standby (ESP) Mission Critical Standby (Exceeds ESP) Standby Data Center Power (DCP) Mission Critical Standby Prime Power 12 Electric Power Division Caterpillar: Confidential Green 6

10/8/19 Data Center Power (DCP) Coverage • Caterpillar does not have DCP ratings • Cover intentions of the ISO rating with existing Cat ratings § Standby/Mission Critical Standby • For areas where grid or other power source acts as normal power source • Can run for the duration of any outage § Prime • For areas where the generator sets are seen as the normal power source • Unlimited hours per year Consult your local Cat Dealer or Cat representative to find the best product/rating for your requirements and location 13 Electric Power Division Caterpillar: Confidential Green Emissions and Ratings EPA Stationary Diesel Regulations • Set minimum emissions regulations for United States • Looks only at application of units, not nameplate rating § Tier 2/3: emergency use only – less strict emissions requirements but strict operational requirements Tier 4 Final: non-emergency use – strict emissions requirements but no operational requirements § • Generator set rating is not related to EPA application definition: EPA concerned with how long and for what use the generator set is running when utility power is available. § Prime power rated generator sets can be emergency (Tier 2/3) § Standby rated generator sets can be non-emergency (Tier 4 Final) Certain locations may have further run hour/emissions regulations • All states, counties, cities, and towns can have specific requirements: can be dependent on location, fuel, number of units/other sources, etc • EPA sets minimum standard in US, but local regulations can set stricter limits for emergency and non- emergency generator sets • Need to consult local AHJ 14 Electric Power Division Caterpillar: Confidential Green 7

10/8/19 Mobile vs Stationary • Mobile § Moves more than once in a 12 month period § Requires the use of EPA Tier 4 Final • Stationary § Emergency Standby: Tier 2/3 § Non-Emergency Standby: EPA Tier 4 Final • Definition of Emergency Standby § No limitation on actual run time (no normal power available) § 100 hours per year limit for non-emergency operation for stationary emergency gensets • Site Testing and Maintenance • Normal power frequency or voltage deviate 5% or greater below standard • Up to 50 hours per year: o Can be used for storm avoidance (no voltage or frequency deviation from normal power) o Cannot be used for peak shaving o Counts towards 100 hours per year limit § Operator must record use and reference to hours meter 15 Electric Power Division Caterpillar: Confidential Green Design for Emergency Preparedness 16 Electric Power Division Caterpillar: Confidential Green 8