Installation Audits - Commissioning Gensets
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Transcript of 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