GPS 200 Genset Fuel (NG vs Diesel) 20180702 · Genset Fuel (NG vs. Diesel) Professional Development...

LEARNER’SGUIDE

GPS 200 Genset Fuel (NG vs Diesel)

Welcome Professional Development Seminar Series

Standby power systems are increasingly in demand. Commercial, industrial, municipal and healthcare facilities are just a few of the markets that require backup power. Generator control systems are a crucial part of the process when designing a system. The ever‐changing requirements of the power generation industry, coupled with requests for additional training, have prompted Generac Power Systems to develop this training program. Titled the Generac Power Systems Professional Development Seminar Series, this program consists of individual training modules that provide both theoretical and practical information. Each module is 90 minutes in length and each incorporate proven learning methodology to ensure a positive experience. These modules are designed to broaden the learner’s understanding of topics such as:

Sizing

Switching

Paralleling

Reliable Design

NEC Requirements

NFPA Standards

Engines & Alternators

Controls

Emissions

Spec Writing

Fuel Choices

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The Module in Perspective

Purpose: The purpose of this course is to provide you with a basic overview of the impact fuel type has on engine operation, genset performance, system reliability, code acceptance, and total cost of ownership. You’ll see how the growth of natural gas generators in the market is replacing some traditional diesel applications. You’ll learn the important role fuel choice and maintenance plays in generator reliability. Difference between rich and lean burn engine technology will also be covered.

TIME: 90 minutes of Classroom Instruction

30 minutes for Final Assessment

LEARNING OBJECTIVES: Upon completion of this module, participants will be able to:

Describe the growth that natural gas generators are having in the standby market

Explain the various failure modes of diesel

Describe the reliability benefits that natural gas has over diesel

Describe the benefits of rich over lean burn engine technology for limited run applications

Explain the impact that natural gas generators have on the total cost of ownership (TCO)

Explain the impact demand response has on TCO for NG vs diesel

CONTINUING EDUCATION: Upon successful completion of this seminar, participants will be awarded a certificate of achievement identifying the seminar title, 2.0 PDHs (Professional Development Hours) and 0.2 CEUs (Continuing Education Units). Successful completion of a PDSS seminar requires that the participant have:

Attended the complete seminar

A minimum score of 80% on the Final Assessment

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Genset Fuel (NG vs. Diesel)

Professional Development Seminar Series – Genset Fuel (NG vs. Diesel)

GPS 200Genset Fuel (NG vs. Diesel)

Professional Development Seminar Series – Genset Fuel (NG vs. Diesel) 2

Topics Covered Estimated TimeGenerator Markets by Fuel…………………….… 20 minStandby Generator Fuel Reliability……………… 30 minGas Engine Technology………………………… 20 minSite & Installation ……………………………...... 10 minTotal Cost of Ownership (TCO)………………...... 10 min

WHAT YOU WILL LEARN

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Generator MarketsBy Fuel


Gas vs. Diesel Market Share• Mobile market

– Dominated by diesel– Portability & power density

• Stationary Market– Gas genset dominate ≤ 150 kW market

Gas generator sets (auto derivative engines) are typically less than diesel

– Diesel gensets dominate the > 500 kW market Diesel has a strong cost and power density advantage

– Gas is a growing percentage of the 150 to 500 kW market

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≤ 150 kW

Gas

Diesel

> 500 kW175 to 500 kW

Frost & SullivanIndustry Data in Dollars

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Natural Gas Growth• Natural Gas has gained 10% market share in 3 years

– Strong customer preference (diesel issues)

– Effects of hurricane Sandy (refueling issues)

– Increased competition in the 175 to 500 kW market

– Emission regulations and cost of EPA tier 4 diesels

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28%

72%

Market Share 2013Gas Diesel

38%

62%

Market Share 2016Gas Diesel

Frost & SullivanIndustry Data in Dollars


Market Applications• Approximately 80% of the generator market is standby

– Backing up the grid (power reliability)

• Non-standby applications– Run hours < 500 hrs / yr (extension of the standby market)

Utility Interruptible & curtailable power programs Energy marketer demand response programs These applications tend to support utility support reliability

– Run hours 1000 - 2000 hrs / yr (energy cost management) Peak shaving & time of day base loading These applications tend to work against the utility revenue

– Run hours > 4000 hrs No utility CHP (combined heat and power) / Co-generation

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Standby

Non-Standby

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EPA constraints

• Non-standby applications (EPA non-emergency rating required)– Gas engines with catalytic post treatment

Slightly lower emission levels than standard standby configurations Standby generators already have catalysts above 85 kW

– Tier 4 Diesel engines (Selective Catalytic Reduction) Increases diesel genset cost by more than 50% Adds complexity and potential reliability issues

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“Demand Response”

• Limited run hour applications supporting grid reliability– Demand Response (transmission / grid reliability)

Calls by Independent System Operator (ISO to reduce load) Open market program that energy companies bid into Energy marketers looking for generator assets to reduce grid load EPA “Demand Response” definition aligns with ISO calls for load reduction

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“Demand Response”

• Limited run hour applications supporting grid reliability– Curtailment / Interruptible programs

Reduction in load or disconnecting from Grid Historically, local distribution company constraint Contract / rate with your energy provider for discounted electricity

– Typical Annual Run hours Maximum 300-500 hrs Average < 50 hrs

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• Demand Response– Cost break from the utility / energy marketer ($ / kW)

Offsets the sunk cost of the standby generator

– Typically use an open or closed transition transfer switch

– Total cost of ownership favors natural gas generators Capital cost of tier 4 diesel Fuel cost (more run hours) Maintenance costs (fuel polishing) More later in presentation

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Demand Response (Standby with an ROI)

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Energy Management (< 2000 hrs)• Energy Management (< 2000 hrs / yr)

– Typically paralleling with the grid (grid interconnect & protection)

– Utilities tend to resist (standby charges, ratchets, etc)

– Typically favors rich-burn gas engine technology (capital cost vs. efficiency)

– Peak shaving - Reducing peak demand charges ($ / peak kW)

Applications with high demand charges with moderate energy charges

– Base loading - Reduced energy charges ($ / kWhr)

Applications with high energy charge applications

Time of Day

New Demand Charge

kW

Remove peak w/on site generation Old Demand

Charge

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GridPower Generator

Produced

Time of Day

kW

Peak ShavingBase Loading


• Combined Heat & Power (CHP)– Applications are typically sized and operated based on heat needs– Heat is taken from engine water jacket, exhaust, & oil– Electricity tends to be the by product– Favors lean-burn gas engine technology (high efficiency)

Energy Management (> 4000 hrs)

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Standby GeneratorFuel Reliability


• Diesel fuel must be maintained to be reliable (NFPA 110 A.7.9.1.2)“Sulfur, naturally occurring gums, waxes, soluble metallic soaps, water, dirt and temperature all degrade fuel as it is handled and stored. These effects begin at the time of fuel refinement and continue until consumption”

“Fuel maintenance and testing should begin the day of installation and first fill to establish a benchmark guideline for further comparison.”

Ultra low sulfur diesel has exasperated fuel issues!!

• Fuel must be tested (NFPA 110 8.3.8)A fuel quality test shall be performed at least annually …

• Fuel must be consumed or cleaned (NFPA 110 7.9.1.3)Tanks shall be sized so that the fuel is consumed within the storage life, or provision shall be made to replace stale fuel with clean fuel.

Why NG Growth? (Diesel Limitations)

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• Ultra Low Sulfur Diesel (via hydrocracking)– More susceptible to micro organism growth – sulfur natural biocide– Higher wax content and increased winter wax gelling– Lower solvency - decreased ability to dissolve injector deposits– Higher formation of peroxides leading to soluble gums


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• Diesel failure modes– Moisture

Normal humidity cycles Keep tank fuel

– Biomass Biomass can grow a water fuel interface Sulfur is a natural biocide (been removed from the fuel)

– Gelling Generators should only be filled with winter blends Primary filter with integrated heaters can help As micron of filter goes down, CFPP increases


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• More diesel failure modes– Running out (NFPA 110 A.5.5.3)

– How much fuel is enough and how much is too much??“Consideration should be given to sizing tanks in order to meet minimum fuel supplier delivery requirements, particularly for small tanks. Consideration also should be given to over-sizing tanks, because many fuels have a shelf life and deteriorate with age.”

“Prudent disaster management could require much larger on-site temporary or permanent fuel storage.”

– Strategies / Considerations Strong fuel-maintenance or fuel-exchange programs Minimize diesel -- Bi-fuel generators (diesel and natural gas) Replace diesel -- Natural gas generators Combined strategy – Parallel diesel & natural gas generators


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• More failure modes associated with fuel transfer schemes– Isolation valves closed (monitor electrically or secure)

– Solenoid failures (solenoid status & bypass)

– Transfer pump failure (lead lag pumps)

– Transfer pump breaker open (monitor electrically or secure)

– Fuel level switch failure (redundant contacts)

– Hot fuel (fuel cooler)

– Generator losing prime (check valve)

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• Mechanical injection systems (simple & reliable)– Mechanical system, sitting in “oil”, limited run hours– Lower injection pressures (3,000 - 5,000 PSI)– Typically 10 micron filters

• ECM / Common rail injection systems (increased complexity)– High injection pressures (30,000 – 40,000 PSI)– Typically 2 micron filters

Why NG Growth? (Diesel Engine Sensitivity)

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• Electronic injection & Exhaust Gas Recirculation (EGR)– Typical on 150 – 500 kW engines (tier 3)

• Diesel Particulate Filters (DPF), – Entering some standby markets (CA near sensitive receptors, NYC)

• Selective Catalytic Reduction (SCR)– All non-standby applications (tier 4 final)

Why NG Growth? (Diesel Engine Complexity)

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• Tier 4 exhaust post treatment complexity

Why NG Growth? (Tier 4 Complexity)

SCR System Sensors

DPF Pressure Drop Sensors

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• Tier 4 failure modes (engine shutdowns)– Diesel exhaust fluid (DEF)

Running out (2% of fuel consumption) Freezing (12⁰F) Evaporation (67.5% water) Contaminated

– Plugging or melting (DOC & DPF) Incomplete regeneration Light duty applications, low exhaust temperatures Build up of fuel & oil

Why NG Growth? (Tier 4 Complexity)

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• Natural gas has a highly reliable infrastructure– Distribution not dependent on electricity– Compressor stations self-powered– Very low probability of cascading failure modes– Four trillion cubic feet of storage (months of fuel without production)– MIT study placed NG reliability at 99.999%

• Two recent studies on natural gas infrastructure reliability– MIT Lincoln Laboratory, May 2013:Interdependence of the Electricity Generation System and the Natural Gas System and Implications for Energy Security

– U.S. Department of Energy, April 2013:Comparing the Impacts of Northeast Hurricanes on Energy Infrastructure

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Why NG Growth? (Natural Gas Reliability)



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• Assessing critical infrastructure resiliency along the East Coast– NG infrastructure magnitudes beyond electric infrastructure and diesel refueling


Text

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• Emergency System Acceptance (NFPA 110)– NFPA 110 assumes NG reliable unless shown otherwise

Why NG Growth? (Increased AHJ acceptance)

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• Emergency System Acceptance (NEC 700)– NEC requires proof of reliability to AHJ satisfaction


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• What is standard for reliability??– NEC does not provide one

– NFPA 20 “fire pumps” standard for reliable utility “electric” Maximum 4 hours outage in previous year No routine power outages Utility does not need to be infallible to be determined reliable

– CMS defined a process for Nursing Homes Letter of reliability from NG utility technical person

– Statement of reasonable reliability

– Brief description supporting statement

– Statement of low probability of interruption

– Brief description supporting statement

– Signature


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18



Gas Engine Technology


Operational differences NG vs. Diesel• Intake stroke

– NG: Air & fuel premixed via carburation (enters via intake valve)

– Diesel: Fuel injected later (air only on intake)

• Compression– NG: Air & fuel pre-mixed is compressed & ignited with spark plug– Diesel: Heat of compression ignites injected diesel– Diesel: Higher compression ratios (more efficient)

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Operational differences NG vs. Diesel• Power stroke

– Diesel: Engines are more power dense (higher efficiency)– NG: Engines typically 30% larger for same output

• Exhaust stroke– Diesel: Engines operate at 900 – 1000F exhaust– NG: Engines (rich-burn) typically have 1300 – 1400F exhaust

This higher temperature limits power density Exhaust valve & turbo charger limitations

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• Turbo Charger Air Cooler (CAC)– Cools the air after compressed by the turbocharger

CAC -- Air to air heat exchanger Intercooler – Air to water heat exchanger in engine

– Type has implications for remote cooling and heat recovery

Turbo Charger Cooling

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• Rich burn (stoichiometric) vs. lean burn– Combustion with excess oxygen (lean burn)– Diesel are always lean burn (only inject needed diesel into excess air)– Gas engines can be designed rich or lean burn

Lean burn technology requires selective catalytic reduction remove NOx Rich burn technology requires AFR & uses a simple 3-way catalytic convertor

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Rich vs. Lean Burn Technology

All diesels&

Specialized gas engines


• Air-fuel-ratio (AFR) control– Creates the optimal mix of air and fuel in the engine– Required when using 3-way catalytic convertors– Constantly oscillates between slightly rich & slightly lean– Oxygen sensor in exhaust stream– Fuel mixture controlled via vacuum control of regulator diaphragm

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Emissions (AFR)

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Emissions (Catalysts)• Oxidizing Catalyst (precious metal)

– Requires fuel lean condition ( > 1.0)

– Lowers CO and HC emissions, Doesn’t effect NOX

• Reducing Catalyst (precious metal)– Requires fuel rich condition ( < 1.0)

– Lowers NOX, Doesn’t effect CO and HC emissions

• Oxidizing & Reducing Catalyst (precious metal – 3 way)– Requires stoichiometric ( = 1.0)

– Lowers NOX, CO, HC emissions

• Life Cycle Cost - Compliant vs. certified– Compliant - Periodic testing – Compliant – User responsible– Certified – OEM responsibile

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• Rich burn (optimized for < 2000 hours / yr)– Better for standby power

Better block loading & 10 second starting Easy to post treat exhaust Better price point

– Lower compression ratio Tolerant of fuel variations & lower octane fuels

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• Lean burn (optimized for > 4000 hours / yr)– Better for combined heat and power (CHP) and base loading power onto grid

Higher efficiency Lower engine direct NOx level (depending on regulations may not need SCR) Typically not optimized for standby – startup, block loading, price point

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OEM’S - Engine Suppliers & Partnerships

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• Caterpillar– Caterpillar & Generac

• Cummins– Cummins & Cummins Npower

• Generac– Generac

• Kohler– PSI & Guascor

• MTU– PSI & MTU

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Site & Installation


• Concerns with natural gas– Supply reliability (utility)

Service capability (pressure & flow) Seismic zones

– Supply reliability (on-site) Pressure drops in piping (Generac sizing tool) Adequate pressure regulators (responsiveness & droop characteristics) Additional loads (boiler, etc) Security of pressure regulators Securing isolation valves

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Site Concerns

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Installation - Piping

• Gas piping requirements– Considerations to pressure regulators, pipe sizing, flexible fuel lines, etc. (110 7.9.9)

– Tapping ahead of the building’s main shutoff for emergency systems (110 7.9.7)

– Securing shutoff valves (110 A.7.9.7)


• Comply with NFPA 30, 37, 54, 58 (NFPA 110 7.9.1.1)

• Piping protected and supported (NFPA 37 6.8.2)

• Remote shutoff valve (away from generator) required (NFPA 37 5.4.1.3)

• Clearly identify (diagram at generator) all fuel shutoff valves (NFPA 37 10.2.2)

• Solenoid valves shall have manual bypass capability (NFPA 110 5.6.3.2.1)

• Flexible fuel line between engine and piping (NFPA 110 7.9.3.2)

• All manual valves should indicate open or closed state (7.9.11)

– Locked open or electrically monitored (not required but good idea)– Key must be accessible (NFPA 37 5.4.1.2)

• Use a utility grade primary pressure regulator– Direct acting (fast responding), Lock-up and & internal relief

Installation - Piping

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Other Fuels

• Land-fill & well head gas– Special engine considerations– Gas quality may be a constraint

BTU value & Corrosive elements in fuel

• Propane – On-site fuel & doesn’t degrade– Considered reliable by AHJ’s– Often configured as dual fuel (≤150 kW)– Low octane fuel – derates significantly in turbocharged engines or not available– Cold weather boil-off rate considerations

Bury the tank, External vaporizers, Use LP liquid generator (vaporize on the generator)

• NG On-site storage– Developing technology (requires high pressure compression equipment)


• Vaporizer (boil of rate solution)– Causes LP liquid to be converted into LP vapor on engine– Not for indoor use (code limitations on LP liquid)

Propane boil rate limitations

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Total Cost of Ownershipwww.GeneratorTCO.com


TCO - Total Cost of Ownership Tool

• Diesel vs. Gas total cost of ownership comparison– Capital, Installation, Maintenance, Fuel– Emissions (soft cost)– Analysis tool at www.GeneratorTCO.com

• Standby applications ≤ 150 kW– The analysis is compelling for natural gas

• Standby application > 150 kW– A long view (life cycle – 25 yrs) needs to be applied– Eventually gas operational cost offsets the higher initial capital cost

• Demand response applications– Tier 4 diesel has higher initial cost (closes gap)– More run hours (gas is cheaper than diesel $/BTU)– The analysis favors natural gas

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TCO – Capital & Installation Costs

• Capital– Favors natural gas (≤150)– Favors diesel (>150)

Not uncommon to be twice as much in larger kW nodes

• Installation costs ($/kW)– Market unique but $150/kW is a good starting point– This assumes typical outdoor configuration (minimal runs)– Inclusive of basic transfer switch equipment– Natural gas piping is a separate item ($10-15/kW initial est.)

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TCO – Fuel Costs

• Fuel operation costs (favors gas)– Unit cost of diesel much greater than natural gas (about x4)

– Gas engines are less efficient but fuel cost offset (net benefit x2)

– Initial fuel fills of large diesel tanks (natural gas pay as you go)

– More run hours favors gas (demand response & limited energy management)

• Fuel maintenance cost (favors gas)– Diesel fuel testing, additives, & polishing– High humidity markets polished fuel often (typically 1 – 2 years)

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TCO – Maintenance Costs

• General Maintenance (same)– Annual Oil change– Belts, Hoses, Batteries

• Load banking (favors gas)– Diesel wet stack (load bank every 2 – 3 years)

– Natural gas (load bank every 5 – 7 years) Validating cooling and engine mechanics

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Total Cost of Ownership (TCO) Tool

• Demand Response– Annual benefit for participating– This creates a payback on a sunk cost (standby generator)– Demand response improves TCO to gas

More run hours (fuel cost) Diesel moves to tier 4 (50% increase in genset cost)

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TCO - Examples

Inputs for Following Examples:(www.GeneratorTCO.com)

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TCO - Examples

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TCO - Emissions

July 3, 201853

• Emissions greatly reduced with Natural Gas– Soft cost bore by society

Questions?

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PROFESSIONAL DEVELOPMENT SEMINAR SERIES

ONLINE FINAL ASSESSMENT AND CERTIFICATE

REGISTRATION AND LOGIN PROCEDURE

Online Final Assessment

Final assessments are available for each PDSS session. These assessments are Web-based and can be accessed using Generac’s online learning system “The Learning Center” (http:// learning.generac.com). PDSS participants are required to obtain a score of at least 80% to pass an assessment. Each online assessment also contains a training survey. The survey provides each participant an opportunity to rate various components of the learning experience along with information relative to business development. Instructions for how to register and log in to this system, take the final assessment and print a certificate, are described in the Registering in “TheLearning Center” section below.

Continuing Education

Upon successful completion of a seminar, participants will be awarded 2.0 PDHs (Professional Development Hours) and 0.2 CEUs (Continuing Education Units). Successful completion of a seminar requires that the participant have:

Attended the complete seminar Received a minimum score of 80% on the Final Assessment

Certificate of Accomplishment

Participants who successfully complete the seminar and receive a passing score on the online final assessment are entitled to a “Certificate of Accomplishment.” Certificates are available for printing directly from the participant’s account screen on Generac’s online training system “TheLearning Center”. Instructions for how to register and log in to this system, take the final assessment and print a certificate, are described beginning in the following section.

Registering in “The Learning Center”

To gain access to “The Learning Center”, you are required to register and set up a user account. During your account setup you will create a Username and Password. Your username and password can then be used to log in on subsequent visits.

The following pages will aid you in the registration process along with the Final Assessment, Survey and Certificate procedures.

To begin the registration process, open your computer’s browser and enter http:// learning.generac.com. This should take you to “The Learning Center”home page. This page is displayed at the top of the next page. From this point you can follow illustrated steps.

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Begin by entering http://learning.generac.com in your computer’s browser. The screen below will be displayed. Click on the “register here” link to begin the registration process.

On this screen you will select “Guest” from the drop down box and click the “Next” button.

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In this next screen enter Access Code 9595 and click the “Next” button. Please keep this code private.

This screen confirms the correct access code entry. Click the “Yes” button to proceed.

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The next screen contains the “User Registration” form. Fill in the required boxes, and then click the “Register” button.

The next screen confirms your registration. Click the “Continue” button to proceed.

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The next screen displays the “Course Catalog.” Click on the “Professional Development Seminar Series” link.

This next screen lists all currently available Final Assessments. Click on the Final Assessment that is tied to the course name and number you completed.

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The next screen is the “Enrollment” screen for the Final Assessment that you selected. Click the “Enroll” link to proceed.

This screen confirms your enrollment. Click the “My Account” button to proceed.

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This is your “My Account” screen. Note that the Final Assessment you selected is displayed under the “Enrollment” tab. Click the “GO” button to proceed.

This screen lists the two parts to the Final Assessment. You must take the “Graded” Assessment first, then the Training Survey.

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In the next screen an “Assessment Code” is required before you can continue. The code for GPS200 Genset Fuel is gen817. Enter the code in the box and click the “Submit” button to continue.

You will now proceed through a ten question assessment. Please read the warnings below.

Professional Development Seminar Series

GPS‐200 Genset Fuel (NG vs Diesel)

Final Assessment

Enter Assessment Code gen817

for “GPS‐200 Genset Fuel (NG vs Diesel)

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Please follow the instructions on this screen. You must wait for your assessment data to be saved. Do not close this window or click the ‘Back’ of ‘Refresh’ buttons on your browser.

This screen confirms that your data was saved. Click on the link shown here to proceed.

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This screen will be displayed after your assessment data is saved. Note that in this example the assessment was passed with a score of 100% and the Survey is unlocked and ready to launch.

Upon launching the Survey, this screen will be displayed. Select the Generac dealer who conducted the seminar you attended.

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After completing the survey you will be prompted to return to the assessment menu. Your response data will be saved as before, and you will see the screen below. Click the “My Account” button to continue.

Your “My Account” screen will look similar to the one shown here. Click the “Print” link to print your certificate.

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NOTES

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Generac Power Systems, Inc.S45 W29290 Hwy. 59Waukesha, WI 53189

1-888-GENERAC (1-888-436-3722)

gene rac .com

Part No. GPS200-20180709-Learner©2018 Generac Power Systems, Inc. All rights reserved.Specifications are subject to change without noticeNo reproduction allowed in any form without prior written consent from Generac Power Systems, Inc.

GPS 200 Genset Fuel (NG vs Diesel) 20180702 · Genset Fuel (NG vs. Diesel) Professional Development...

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