Application Installation of Generators.pdf
- 1. Page1 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Basic A&I Application & Installation of Generators Jessica Treadway - February 2017
- 2. Page2 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas What is A&I? CATERPILLAR CONFIDENTIAL:GREEN
- 3. “A&I” is Application and Installation engineering technical support… Page3 CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas
- 4. Agenda Page4 CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas • Engine RoomDesign • Air IntakeSystems • CoolingSystems • ExhaustSystems • FuelSystems • Engine RoomVentilation • Foundations &Isolation
- 5. Page5 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Engine Room Design
- 6. Engine Room Design Considerations • Single or Multiple Use Facility • Single or Multiple Generators • Prime Power or Standby • Ventilation Requirements • Cooling Requirements • Serviceability • Clearances • Access
- 7. Single or Multiple Use Facility Single Use Facility This room is primarily dedicated to generators. Multiple Use Facility The multi use facility would not only have generator sets, but also auxiliary equipment such as boiler units, compressors, etc.
- 10. Service Convenience • Compressed Air • Ventilation Air • Water • Emergency Wash Station • Fire Suppression System • Cable Routing • Load Testing
- 11. Clearances • Lifting Capabilities • Overhead Clearances • Side Clearances • Front and Rear Clearances • Underneath Clearance • Electrical Connections
- 12. Access • DoorWidth • Access forRoutine Maintenance • MajorRepair • ServiceElevator
- 13. Several Other Considerations • Emergency/Rental Generator • Expansion (future genset) • Installation Considerations - Lift Points • Total Package Weight • Engine Storage • Removing Moisture in Generators • Flooring Considerations • Rooftop Installations • Fire & Explosion Prevention • Lines, Tubes & Hoses
- 14. Page14 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Air Intake Systems
- 15. • Dirt and debris ingested into the engine are a major source of wear on moving engine parts. • The air intake is a significant path for dirt and debris to enter the engine. • Sources of dirt and debris in the air intake include: – Materials left from initial fabrication and assembly of ducts – Filter changes – Air intake duct leaks – Environment Air Cleanliness
- 16. Particles in Intake Air • Particles under 0.001mm (1 micron) diameter have little effect and will pass out through the exhaust • Particles from 0.001 – 0.01mm (1-10 microns) diameter have a measurable effect on the engine – The average human hair is 0.08mm (80 microns) in diameter • One teaspoon of 0.125mm (125 microns) diameter dust per hour will create catastrophic failure of an engine in 24 hours
- 17. Air Cleaner Configurations • Engine mounted • Remote mounted • Multiple element • Multi-stage (Precleaners)
- 18. • May be a requirement of the site configuration • Best practice to leave engine-mounted air cleaners on the engine and route ducts from them • For remote-mounted air cleaners, ducts must be completely sealed to ensure all intake air is drawn through the filter elements Air Intake Ducts
- 19. • Varies according to engine model, rating and fuel • Provided on technical data sheet in both volumetric and mass flow terms • Establishes total flow requirement for use in design of the site air intake system • Used in restriction calculations Combustion Air Flow Requirements
- 20. Page20 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Cooling Systems
- 21. Engine Heat Balance Internal Heat ~ 25% - 35% Mechanical Work 30%-40% Exhaust Energy ~ 30%-35% Radiation ~ 5%
- 22. Review of the Basics Internal heat is removed by: – Jacket water – Oil cooler – Aftercooler Oil cooler heat load is included in the jacket water heat load on diesel engines and in the aftercooler heat load on most gas engines.
- 23. Review of the Basics Cooling system is defined by how the aftercooler heat is handled: – JWAC jacket water aftercooled – SCAC separate circuit aftercooled – ATAAC air to air aftercooled – Two stage aftercooler (JWAC+SCAC)
- 25. Radiator Height Limits If more than 57ft vertical distance from JW pump to highest point in cooling circuit, a hot well or heat exchanger is needed to keep static head pressure below seal limits.
- 26. – Try to design room to ½” H2O restriction – Plan cooling at ¾” H2O restriction • Walls at the air exit should be 2 fan diameters or more away from the radiator • Louvers typically require an additional 25-95% opening, heavy duty bird screen material, 20-40% Radiator Air Flow
- 27. Radiator Sizing Need to Know: – Heat rejection to JW and AC – Radiant heat added to room – Room air restriction (if installed radiator) – Line loss and pump flow rate (if remote radiator) – Site altitude – Max ambient temperature
- 28. Heat Rise • Heat Rise - Potential temp rise as intake air moves across gen-set Example for Caterpillar Diesel Engines: – Tier 2 engine in a power room: 4oC heat rise – Tier 4 engine with CEM in a power room: 6oC heat rise – Tier 2 engine in an enclosure: 7oC heat rise • THESE ARE MINIMUM VALUES • When specifying, make sure to clarify location of ambient temp or specify cooling system capability including heat rise.
- 29. Line Restriction – Always keep external restriction between the limits shown for the pump in technical information – Too much restriction • Too little flow to cool the engine • Cavitation that ruins the pump – Too little restriction • Too much velocity erodes the cooling system
- 30. Venting – Vent lines or air release valves are needed at every air trap point. – Vent lines need to be constantly rising until they reach the highest point in the system. – Air release valves use a float and spring to keep the system closed until steam builds up in a cavity.
- 31. Page31 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Exhaust Systems
- 32. Exhaust System Considerations • Minimize back pressure • Reduce noise • Provide adequate clearance • Ensure proper mounting
- 33. Back Pressure • Target – Half the maximum allowable systemback pressure • CommonCulprits – Exhaust pipe diameter – Sharp bends – Exhaust pipe length – Silencer resistance • Calculate andMeasure
- 34. Noise Reduction • Determine AttenuationLevel – Residential – Critical – Supercritical • Selecting aSilencer – Balance sound attenuation with back pressure – Space, Cost, Appearance
- 35. Clearance and Mounting •Clearance – Overhead cranes – Minimum 9 inches from combustible materials – Air intake •Mounting – Flexible connections – Weight support
- 36. Page36 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Fuel Systems
- 37. Diesel Fuel Supply System • Fuel StorageSystem • Fuel TransferSystem • Fuel FiltrationSystem
- 38. Fuel Storage System • Main Tank – Sizing Rule of Thumb: Fuel Consumption Rate x Hours Between Refills » (at 100% load factor depending on application) – 660 Rule • Day Tank – Required when main fuel tank is: • Same level, > 50 ft away • > 12 ft below engine • Above engine fuel injectors
- 39. Fuel Transfer System • Fuel Pump Capability and DesignConsiderations – Vertical distance from tank to pump – Internal piping system losses – Elevation •Routing – Avoid hot surfaces – Avoid formation of traps – Low to the ground
- 40. Fuel Filtration System • Engine fuel filters must never be removedor bypassed • Removal of water andsediment – Water separator – Coalescing filter – Centrifuge
- 41. Page41 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Engine Room Ventilation
- 42. Ventilation • Remove Radiant and Convection Heat – Genset and Switchgear performance – Adequate conditions for personnel • Engine Room Temperature Rise – 8.5oC to 12.5oC – Never exceed 49oC • Air Velocity – 1.5 m/s in working areas
- 43. Ventilation Considerations • Direction – Cool, dry, clean air – Low entry – Horizontal air flow – Generator first
- 44. Ventilation Considerations • Routing – Entry as far and low as possible – Discharge as high as possible – Do not blow cool air toward hot engine components
- 49. Incorrect Flow Single Engine
- 52. Required Air Flow – Engine room ventilation can be estimated by the following formula, assuming 38oC (100oF) ambient air temperature:
- 53. Page53 Electric Power | Marine | Oil & Gas CATERPILLAR CONFIDENTIAL:GREEN Electric Power | Marine | Oil & Gas Foundations & Isolation
- 54. Functional Requirements for Foundations • Support total weight (mass) & dynamic loading of equipment, accessory equipment and fluids (coolant, oil and fuel) • Maintain alignment between engine, driven equipment, and accessory equipment • Isolate equipment vibration from surrounding structures
- 55. Base Material • Material supporting the foundation must carrythe total weight – Firm level soil, gravel, or rock – Fine clay, loose sand, or sand near ground water level • Seasonalchanges – Extend foundations below the frost line
- 56. Concrete Foundations • Avoid excessively thick bases • For paralleled units foundation must withstand twice the weight • Minimum 12 inch edge clearance • Mass no less than mass of equipment • Depth to attain minimum weight 𝐹𝐷 = 𝑊 ÷ (𝐷 × 𝐵 × 𝐿) FD = Foundation Depth W = Total Weight of Equipment D = Density of Concrete B = Foundation Width L = Foundation Length
- 57. Functional Requirements for Package Isolators • Limit vibrations transmitted from genset to foundation • Ensure that package rigid body vibration modes stay clear of engine excitation frequencies • Correct for small variations in foundation surface flatness – Generally, isolators used on electric power gensets can not correct for foundation flexure under dynamic loads!
- 58. Isolators • Manytypes – Rubber – Gravel or Sand (Bulk Isolation) – Spring
- 59. Summary • Engine RoomDesign • Air IntakeSystems • CoolingSystems • ExhaustSystems • FuelSystems • Engine RoomVentilation • Foundations &Isolation
- 60. Questions ?