GE - Dimensionnement optimal vs Uptime - Buess.ppsx

DC Forum - Coppet, le 17 septembre 2014

Avesco - Energy Systems

Gian Franco Broggi Loris Buess

Avesco – Une entreprise familiale

Equipements de chantier

Production d’énergie

Equipements de compactage

Centrales à béton et d’asphalte

3’400 employés Chiffre d’affaire 2013 : 910 MioCHF

Fondé en 1869 6e génération

Sièges d’Avesco et Ammann à Langenthal/BE

- Plus de 1’000 collaborateurs sur le site - Plus de 120 apprentis - Plus de 100 collaborateurs pour Avesco

Energy Systems

Avesco Energy Systems - Succursale Suisse Romande

• Avesco à Puidoux : plus de 50 collaborateurs • Siège de la société Avesco Rent SA • Avesco Energy Systems : depuis le 1er juillet 2014 à Puidoux • Une équipe motivée et proche de vous • Conseil de vente, réalisation de projet, service • Hotline 24/7 en français

Des installations de secours clés en main

Engineering Systèmes de contrôle Installation complète Transport et montage Tests en usine

Power Systems : en croissance

- La société opère principalement dans 3 segments de produits - Resource Industries - Construction Industries - Power Systems

- Selon Caterpillar : “Global economic growth will drive increasing demand for energy and transportation during the coming decades”

- Cat dans le monde :125 000 employés - Il y a plus de 450’000 génératrices Cat

installées dans le monde.

Europe, Africa & Middle East

• La région EAME constitue une importante unité de production ainsi que la plus grande division de distribution Caterpillar en dehors des États-Unis.

• Le siège de Caterpillar EAME-CIS se trouve à Genève • Les distributeurs Cat® de la région EAME emploient plus de 26’000

personnes. • Avesco est le distributeur exclusif de Caterpillar en Suisse depuis

1931.

Groupes électrogènes

Comment assurer un dimensionnement optimal en

fonction des critères de l’Uptime Institute

Loris Buess, Caterpillar

17 Septembre 2014

TRANSFORMED BY 6 SIGMA

One powerful future.

Page 2 | CATERPILLAR CONFIDENTIAL: YELLOW

“The generator set shall be rated 2MW

continuous”




Ratings

Data Center Genset Usage

Complying with Uptime Requirements




What are ratings?

• Approved methods of applying gensets

• Gensets with different ratings are not necessarily

different gensets

• Ratings are trade-offs between:

– Run-hours

– Average load (Load Factor)

– Max power available




ISO8528-1

• ISO = International Standards Organization

• Developed to provide consistency across

manufacturers and industries

• Defines 4 ratings:

– Continuous Power (COP)

– Prime Power (PRP)

– Limited-Time Running Power (LTP)

– Emergency Standby Power (ESP)

• Manufacturers usually use different specifications




ISO vs Caterpillar

ISO 8528-1 Ratings

• Emergency Standby

• No ISO equivalent

• No ISO equivalent

• Limited-Time Running

• Prime Power

• Continuous Power

Caterpillar Ratings

• Emergency Standby

• Standby

• Mission Critical Standby

• Load Management

• Prime

• Continuous




Rating Trade-offs

1250

1500

1750

2000

2250

2500

1 2 3 4 5

Overload

Nameplate

Avg Load

Continuous PrimeLoad Mgmt

MCStandby Standby

Un

limit

ed H

rs

Un

limit

ed H

rs

500

Hrs

500

Hrs

500

Hrs

Avg Load vs Load Variation & Peak Demand

Run Hours vs Avg Load

Avg Load vs Peak Demand

+10%Overload




Ratings: Common Approaches

• Designing for worst-case scenarios is the norm

– Max possible load

– Worst possible ambient conditions

• Doesn’t reflect real world operation

• Under-loading concerns

• Doesn’t provide optimal value




Real World Usage

Includes Commissioning

Tests

1000

1250

1500

1750

2000

2250

2500

1 2 3 4 5 6Continuous PrimeLoad Mgmt

MCStandby Standby

1 hr in 12

(25 Max)

Un

limit

ed H

rs

Un

limit

ed H

rs

500

Hrs

500

Hrs

500

Hrs

Data CenterHistograms

• 78 Units (2006-2010 delivery)• Avg hours per year = 130• Max hours per year = 238 hrs

AVG LF

• Avg Load Factor = 49%• Avg time @ nameplate = <0.5%• Avg time >85% = ~14.25%

130

Hr

AV

G




Real World Usage

Under-loading Concerns?

MC Standby




Uptime Requirements

• Tier Standards:

“Engine generators for Tier III and IV sites shall not have a limitation

on consecutive hours of operation when loaded to ‘N’ demand.”

(Topology paper section 2.5.2)

• Key Uptime requirements

– No limitations on consecutive run hours

– No limitations on load factor




Uptime Compliance

• No limitations on consecutive run hours

Caterpillar’s Mission Critical Rating:

“Output available with varying load for the duration of

the interruption of the normal source power. Average

power output is 85% of the standby power rating. Typical

operation is 200 hours per year, with maximum expected

usage of 500 hours per year.”

• Maintenance consequences…




Uptime Compliance

• No limitations on load factor

– Generator set will not see 100% load factor over

extended periods of time.

• Load is vary rarely close to 100% (see Real World data)

• UPS recharge: 10 to 20% of UPS load

• Chillers/CRACs will cycle based on time of day / season

• Caterpillar’s standby and mission critical standby

ratings comply with Tier III and IV requirements




Compliance process

• Project-specific

• Reviewed, validated and signed by an Caterpillar

person recognized by the Uptime

• Highlights compliance with Uptime Tier III and IV

standards

• Allows to optimize the sizing of your Generator Set




Conclusion

Work with experts to size your system

See you at the stand!

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