Informe Mínimo Técnico Central de Respaldo Los Cóndores PDF
Informe Mínimo Técnico Central de Respaldo Los Cóndores PDF
Informe Mínimo Técnico Central de Respaldo Los Cóndores PDF
Cerro Colorado 5240, Of. 1601, Ed. Torre del Parque II,
Las Condes, Zip Code 7560995 - Santiago – CHILE
tel. +56 2 2715 8000 - fax +56 2 2715 8001
[email protected]
tractebel-engie.com
INFORME TÉCNICO
RESTRINGIDO
C 13/08/2019 Revisión Cliente Rodrigo Trujillo Ismael Rodríguez Eduardo Andrzejewski Eduardo Andrzejewski
B 01/08/2019 Revisión Cliente Rodrigo Trujillo Ismael Rodríguez Eduardo Andrzejewski Eduardo Andrzejewski
A 25/07/2019 Revisión Interna Rodrigo Trujillo Ismael Rodríguez Eduardo Andrzejewski Eduardo Andrzejewski
TRACTEBEL ENGINEERING S.A. – registered office: Cerro Colorado, 5240, Of 1601, Las Condes Torre II - Zip Code 7560995 - Santiago - CHILE
DETERMINACIÓN DE MÍNIMOS TÉCNICOS – CENTRAL LOS CÓNDORES
TABLA DE CONTENIDO
RESUMEN EJECUTIVO ............................................................................................................... 3
1. OBJETIVO ............................................................................................................................... 4
6. CONCLUSIONES.................................................................................................................. 11
7. ANEXOS ............................................................................................................................... 12
Mínimo Técnico de 468 kWe por unidad generadora, cuyo valor está
fundamentado bajos las recomendaciones del fabricante de las unidades
generadoras y los registros operacionales obtenidos en las pruebas FAT.
2. DEFINICIONES Y ABREVIACIONES
Definiciones
Se entenderá por Mínimo Técnico la potencia activa bruta mínima con la cual una
Mínimo Técnico unidad puede operar en forma permanente, segura y estable inyectando energía al
SI en forma continua.
Tabla 1. Definiciones
Abreviaciones
MT Mínimo Técnico
FP Factor de Potencia
SI Sistema Interconectado
UN Unidad N
Tabla 2. Abreviaciones
2. Recomendaciones del Fabricante MTU: Grupo Electrógeno Diésel MTU 16V DS2500
4. DESCRIPCIÓN DE LA CENTRAL
La Central Los Cóndores, propiedad de Prime Energía Spa, se compone de 56 grupos
electrógenos diésel idénticos divididos en 4 naves. En la Tabla 4 se indican los
parámetros principales de cada unidad generadora:
N-1 U1 - U14 25
5. MÍNIMO TÉCNICO
Se requiere determinar y respaldar el Mínimo Técnico de las unidades generadoras de
la central Los Cóndores. En los siguientes capítulos se indican y desarrollan las
justificativas basadas de acuerdo con los siguientes criterios:
1 Aplicable para suministros de energía de carga variable por una cantidad ilimitada de horas, acorde a la norma ISO
8528. Se permite una sobrecarga del 10% según normas ISO3046, AS2789, DIN6271 Y BS5514.
De manera adicional, se indica que el motor operando a bajas cargas puede mostrar el
fenómeno denominado como ““Wet Stacking” (ducto de escape húmedo). A
continuación de muestra un extracto de la carta enviada por el fabricante MTU:
Mayor detalle del fenómeno mencionado anteriormente puede ser visto en la infografía
del proveedor Clifford Power (ver Anexo C).
NFPA
La Asociación Nacional de Protección contra el Fuego (NFPA por sus siglas en inglés),
advierte en su estándar número 110, de generadores de emergencia y standby, sobre
el fenómeno “Wet Stacking”. Esto se previene operando el motor con cargas sobre el
30% de la potencia nominal.
Aurora Generators
Cummins
Figura 4. Precaución de operación con baja temperatura de refrigerante (60°C; Manual de operación
Cummins)
2000
Potencia Activa [kW]
1500
1000
500
De acuerdo con la Figura 5, el grupo electrógeno presenta una operación estable para
todos los niveles de carga, el incluso el más bajo, que corresponde al 25 % de la
potencia nominal, cuyo valor es 468 kW.
Los documentos de las pruebas FAT con los cuales fue trazada la curva de la Figura 5,
pueden ser encontrados en el Anexo A.
Potencia
Mínimo Técnico Mínimo Técnico
Central Nominal Fabricante
[kW] [%Pnom]]
[kW]
La Portada– U1-U3-
1.000 250 25% Cummins
U6
Además, en la sección 5.2, se presentan los resultados de las pruebas FAT realizadas
por MTU a sus unidades generadoras. Durante las pruebas ejecutadas en fabrica, la
mínima carga probada corresponde a la potencia mínima declarada 468 kW e.
4 Datos técnicos
4.1 DG16V4000A2E (3G, optimizado en emisiones de gas de
escape según NEA paraORDE)
Datos de potencia del grupo electrógeno
Potencia con aire de aspiración de 34 °C y altura de empleo de 100 m sobre el nivel del mar.
Generador modelo: Leroy Somer LSA 52.3 L12 / 4p
Tensión (V) 415
Frecuencia (Hz) 50
Potencia (kWel) 1872
Potencia (kVA)* 2340
Intensidad (A) 3255
*cos phi = 0,8
Sistema de combustible
Altura máx. de aspiración de combustible m 5
Caudal de admisión máx. de combustible l/min 20
TIM-ID: 0000083999 - 001
Sistema de refrigeración
Caudal volumétrico del líquido refrigerante del motor m3/h 68,5
Caudal volumétrico del líquido refrigerante del aire de sobrealimen- m3/h 30
tación
Calor evacuado por el líquido refrigerante del motor kW 660
Calor evacuado del aire de sobrealimentación kW 430
Calor de radiación y por convección del motor kW 90
Sistema de escape
Temperatura del gas de escape (después del turbosobrealimenta- °C 480
dor)
Caudal volumétrico del gas de escape m3/s 6,6
Sobrepresión máx. del gas de escape mbares 85
Sobrepresión mín. del gas de escape mbares 30
Dimensiones y pesos
Grupo electrógeno
Peso (seco) Véase el plano de montaje
Longitud MTUA-001076-00-MEC-PM-0001-xx
Anchura
Altura
TIM-ID: 0000083999 - 001
Ventajas
• Amplia gama de grupos electrógenos estandarizados para responder a las necesidades del cliente en
cuanto a potencia, emisiones y otras prestaciones
• Posibilidad de selección entre diversos componentes (p. ej. filtro previo de combustible) y opciones (p. ej.
refrigerador de combustible)
• La tecnología más moderna de motores diesel
• Los componentes principales más innovadores para un mayor rendimiento y una larga vida útil
TIM-ID: 0000083986 - 001
2 MODEL DG16V4000A2E
3 SERIAL 0
4 RATING 3G_LTP
5 RPM 1500
6 HZ 50 Hz
7 KW 1872 1
2
8 KVA 2340 3
4
9 MASS KG 14.000
5 6
10 VOLTS 415 7 8
9
11 AMPS 3255
10 11 12
12 PF 0,8
13
13 AMBIENT °C 40°C 14
15
14 ALTITUDE m
16
15 PERFORMANCE CLASS G3
17
16 MANUFACTURE YEAR 00.01.1900
17 CE-Patch -
Projekt: 1325096_Prime Energia 12_548100389 Datum: 06.02.2019
Bearbeiter: AN 518285
Firma: MTU Onsite Energy Systems GmbH
Main data M 1
Generator type: LSA 52.3 L12 / 4p 1
Power: 2 394 kVA 1 915 kWe 1 987 kWm 1
Voltage: 415 V Star serial 1
Rated voltage range: +5/-5% 1
Power factor - Lagging: 0,8 1
Frequency: 50 Hz 1
Speed: 1500 rpm 1
Nominal current: 3 331 A 1
Winding type: p2/3 1
Classes (Insulation / Temperature Rise): H/F 1
Ambient Temperature: 40 °C 1
Altitude: 1000 m 1
-
Installation 1
Client: MTU Friedrichshafen GmbH CRM 1
Project: Chile 1
Site: Chile 1
Prime mover: Reciprocating engine 1
Manufacturer: MTU 1
Type: 16V 4000 1
Duty: Base Rating 1
Industry: Construction 1
-
Mechanical Construction IM1201 1
Type of construction: Single bearing 1
Mounting arrangement: Horizontal Axis 1
Direction of rotation: Clockwise (seen when facing the drive end - DE) 1
Bearing type: Anti-friction 1
Bearing Lubrication: Regreasable 1
Bearing insulation: Not insulated 1
Flector type: SAE 21 1
Balancing - Class (ISO 1940/1): Without key - G2,5 (std) 1
Flange: SAE 00 1
Shaft height: 500 mm 1
Width: 750 mm 1
-
Additional specificities 1
Stabilized Runaway speed: 2250 rpm - 2 min. 1
-
Cooling Method IC01 1
Degree of protection: IP23 1
Coolant: Air / Temperature: 40 °C 1
Air quality: Clean 1
Ventilation (internal): Self-ventilated 1
Filters: Without 1
Ducting for air inlet: No 1
Ducting for air outlet: No 1
-
Connection, Excitation & Regulation 1
Parallel operation: With mains (3F) 1
Excitation: Self-excited - Brushless - Type: PMG 1
Sustained 3-phase Isc: > 3 x FLC for 10s. 1
AVR type: D510C - Digital 1
AVR location: In terminal box 1
Alternator Voltage sensing: In terminal box 1
Additional features:
Three-phase sensing 1
Diode failure detector 1
-
Terminal box
Power connection: 4 connectors (brought out neutral) 1
Main Terminal box location: On Top 1
Line side outlet: Right hand side (seen when facing the drive end - D) 1
Gland plate: Standard - Cable gland plate not drilled 1
-
Protection and measurement accessories 1
1
Temperature detection 1
Stator windings: 6 x 3-wire Pt100 RTDs 1
Guide bearing - NDE: 1 x 3-wire Pt100 RTD 1
1
Anti-condensation heating 1
Voltage: 230 V - 1Ph / Power: 500 W 1
-
Transformers (Client use)
LS Supply 1
Set of 3 x CTs (measuring and/or protection): I Primary / I Secondary / Power / Class
Preliminary Neutral side S1 4000 / 1A / 10VA / Cl. 0,5 FS5 1
S2 4000 / 1A / 10VA / Cl. 5P10 1
1
-
Various items 171206YV03_B
Paint: C3M-P - Polyurethane - RAL acc. to MTU request 1
Documentation: PDF manual 1
Documentation Language: English 1
-
Controls
QUAL/INES/006 001 Measurement of winding resistance 1
QUAL/INES/006 021 Insulation check on sensors (when fitted) 1
QUAL/INES/006 002 Voltage balance and phase order check 1
QUAL/INES/006 007 Overspeed test (according to test bench limitation) 1
QUAL/INES/006 009 High potential test 1
QUAL/INES/006 010 Insulation resistance measurement 1
-
Main data: M
Power: 2 394 kVA 1 915 kWe 1 987 kWm 1
Voltage: 415 V Frequency: 50 Hz 1
Rated voltage range: +5% / -5% Speed: 1500 rpm 1
Power factor - Lagging: 0,8 1
Nominal current: 3 331 A Phases 3
Insulation / Temperature rise: H/F Connexion Star serial 1
Cooling: IC01 Winding type: p2/3 1
Winding: - 6 Wires 1
Ambient Temperature: 40 °C 1
Altitude: 1000 m Overspeed (rpm) 2250 1
Duty: Base Rating Total Harmonic Distortion (THD) < 5% 1
Resistances (%)
Ra 1,4 Armature resistance R0 0,8 Zero sequence resistance 1
X/R 7,4 X/R ratio (without unit) R2 2,4 Negative sequence resistance
Umax + 5% 436 V
Capability Curve Un 415 V
Umin - 5% 394 V
kWe
kWe // rated
ratedkVA
kVA
PF -0,8 PF -0,9 PF -0.95 PF 0.95 PF 0,9 PF 0,8
1 0.8
PF -0,7 PF 0,7
0,8
PF -0,6 PF 0,6
0,6
PF -0,5 PF 0,5
PF -0,4 PF 0,4
0,4
PF -0,3 PF 0,3
PF -0,1 PF 0,1
0
-1,0 -0,8 -0,6 -0,4 -0,2 0,0 0,2 0,4 0,6 0,8 1,0
kVAr
kVAr// rated kVA
rated kVA
PF 1 PF 0,8
98,00.0
97,00.0
96,500.0
96,540.0
96,337.6 96,381.3
96,00.0 96,272.5
95,500.0
95,179.7
95,00.0
94,638.6
94,500.0
94,00.0
25 50 75 100 125
Load (% of rated kWe) - Charge (% kWe nominaux)
Isc ( Short circuit current per rated current - Courant de court circuit / In )
Symetrical Phase to neutral short circuit
14 Symetrical two phase short circuit
Symetrical three phase short circuit
12 Thermal limit curve
court circuit aux bornes de l'alternateur
short circuit at generator terminals -
10
0
0,001 0,01 0,1 1 10 100
Time - Temps (second.)
Isc ( Short circuit current per rated current - Courant de court circuit / In )
Symetrical three phase short circuit (rms)
30
Asymetrical three phase short circuit (peak)
25
court circuit aux bornes
20
15
10
0
0,001 0,01 0,1 1 10 100
Time - Temps (second.)
5%
10%
15%
20%
25%
30%
35%
40%
PF = 0,8 PF = 0,6 PF = 0,3 PF = 0 100%
35%
Voltage rise - Surtension (% of rated voltage)
30%
25%
20%
15%
10%
5%
0%
0 1 000 2 000 3 000 4 000 5 000 6 000 7 000
PF = 0,8 100%
Stator current
(per rated current)
6
5,5
4,5
3,5
2,5
1,5
1
1 10 100 1000 10000
Maximum duration - durée maximum (second.)
2 50 C
B
1 25
A
0 0
1 10 100 1000 10000 0 1 2 3 4 5 6 7 8 9 10 11 12
Maximum duration of fault - Maximum duration of fault -
Durée max. du defaut (second.) Durée max. du defaut (second.)
Date 08.06.2018
Dear Sirs,
For your Project Quickstart 475 MW Chile you asked about the Low Load operation capability for
an
Engine type 16V4000G24F
Emission optimization NEA
Application Group “Grid Stability” 3B
For this specific project only, we can provide the following approval:
Continuous Engine operation at loads between 115 kWm and 480 kWm should be avoided:
The Cylinder Cutout function is inactive at loads higher than approx. 115 kWm, the engine
operates then in full engine mode. This leads to a temperature decrease in the engine and
therefore to an inappropriate operation mode for long time operation. At loads higher than 480
kWm, the load is sufficient to ensure an acceptable level of engine temperature.
Please take in account that the engine will show “Wet Stacking”. This means that at low load, oil
traces may appear on the outside of the engine caused by oil accumulation in the exhaust pipe.
These oil leakages will have no effect on reliability, load acceptance, maintenance schedule or any
other technical data of the engine. For further information please refer to our White Paper
“Information about Wet Stacking on Diesel Engines”.
MTU Friedrichshafen GmbH
i.A. Robert Welz
2
TM
Information Sheet # 09
Wet Stacking of Generator Sets
Your Reliable Guide for Power Solutions and How to Avoid It
1.0 Introduction
Most standby generator systems up to five megawatts use the reciprocating internal combustion engine as the power source to drive the generator that produces the
electrical power. The engines of choice are either diesel, natural gas or LPG fueled. A large percentage of standby power systems use the diesel engine. Diesel is a
convenient independent fuel source and the compression ignition systems of diesel engines have a much higher thermal efficiency than the spark ignition system used
by gas engines. However, one factor to be considered when selecting a diesel power source is the potential for “wet stacking.”
The National Fire Protection Agency (NFPA), in their NFPA 110 Code for Emergency and Standby Power Systems section 6 - 4.2 (1996 edition) refer to wet stacking as a
field term indicating the presence of unburned fuel or carbon in the exhaust system. The later 1999 edition suggests a more quantitative method for determining the
presence of wet stacking by measuring the exhaust gas temperature, explained later in this information sheet.
This information sheet discusses the causes of wet stacking, its effect on the engine, why it should be avoided and methods for eliminating the condition.
The designer of a generator system must take into account the potential for wet stacking when determining equipment for the system, load calculations and maintenance
and service programs. The system designer should consider the following.
2.0 Causes of Wet Stacking:
Like all internal combustion engines, to operate at maximum efficiency a diesel engine has to have exactly the right air-to-fuel ratio and be able to sustain its designed
operational temperature for a complete burn of fuel. When a diesel engine is operated on light loads, it will not attain its correct operating temperature. When the
diesel engine runs below its designed operating temperature for extended periods, unburned fuel is exhausted and noticed as wetness in the exhaust system, hence the
phrase wet stacking. (Continued over)
Valve
Deposits on valve seats and stems will lower
performance and cause wear
Piston
Lube Oil
Deposits start building up on piston and rings
By pass of rings into oil pan leading to loss of performance and wear
will dilute the oils
lubricating properties
Copyright PLC Enterprises LLC
To fulfill our commitment to be the leading supplier and preferred service provider in the Power Generation Industry, the Clifford
Power Systems, Inc. team maintains up-to-date technology and information standards on Power Industry changes, regulations
and trends. As a service, our Information Sheets are circulated on a regular basis, to existing and potential Power Customers
to maintain awareness of changes and developments in engineering standards, electrical codes, and technology impacting the
Power Generation Industry.
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3.0 Engine Effect
When unburned fuel is exhausted out of the combustion chamber, it starts to build up in the exhaust side of the engine, resulting in fouled injectors and
a buildup of carbon on the exhaust valves, turbo charger and exhaust.
Excessive deposits can result in a loss of engine performance as gases bypass valve seatings, exhaust buildup produces back pressure, and deposits on
the turbo blades reduces turbo efficiency.
Permanent damage will not be incurred over short periods, but over longer periods, deposits will scar and erode key engine surfaces. (Diagram One)
Also, when engines run below the designed operational temperature, the piston rings do not expand sufficiently to adequately seal the space between
Corporate Office the pistons and the cylinder walls. This results in unburned fuel and gases escaping into the oil pan and diluting the lubricating properties of the oil,
P.O. Box 581807 leading to premature engine wear.
Tulsa, OK 74158-1807 3.0 Why To Avoid Wet Stacking
800.324.0066
In addition to the adverse engine effect, the designer and user of a system have to consider:
• Expense - Excessive wet stacking will shorten engine life by many years and before planned replacement.
• Pollution - Many urban areas restrict the level of smoke emissions wet stacking produces.
Tulsa • Power - Even before an engine is damaged, deposits will reduce maximum power. A prematurely worn engine will have a lower maximum power
9310 East 46th Street North
Tulsa, OK 74117
than it was designed to develop.
918.836.0068 • Maintenance - An engine experiencing wet stacking will require considerable more maintenance than an engine that is adequately loaded.
4.0 NFPA Guidelines
Wet stacking is a recognized condition with organizations that write codes for standby generator set systems, such as the National Fire Protection
Oklahoma City Association (NFPA) which has issued several guide lines for controlling the effects.
7300 Melrose Lane
The NFPA guidelines in Level 1 and 2 applications require exercising the unit at least monthly for 30 minutes under either of two methods:
Oklahoma City, OK 73127
405.949.2332 1. Under operating temperature conditions and not less than 30 percent of the EPS name plate kW rating, or
2. Loading to maintain the minimum exhaust gas temperature as recommended by the manufacturer. (See NFPA 8.4.2.) Exhaust gas temperature
specifications are available from the manufacturer of the unit.
Little Rock 5.0 Additional Conditions
6800 Intersate 30
The Joint Commission on Accreditation of Health Care Organizations (JCAHO), the organization that accredits health care institutions, has taken this
Little Rock, AR 72209
501.907.5884 testing to a level beyond the NFPA. They require testing of 12 times per year with testing intervals between 20-40 days. Testing generators for at least
30 minutes under a dynamic load of 30% or greater of the name plate rating.
Systems that do not meet the 30% load capacity have three options.
Kansas City 1. Increase the load to meet or exceed 30% of the name plate rating,
211 E Marley Rd 2. Maintain the minimum exhaust temperature as recommended by the engine manufacturer, or
Kansas City, KS 66115
913.312.2031 3. Undertake load bank testing for a total of 2 hours continuous loading as follows: a) Load at 25% of name plate for 30 minutes b) 50% for 30
minutes c) 75% for 60 minutes.
JCAHO also recommends that all automatic transfer switches (ATS) are tested 12 times per year at 20 and 40 day intervals. The provider of the power
system through planned maintenance programs can undertake load testing when testing the ATS.
St. Louis
53 Millwell Court 6.0 Solutions to wet stacking:
Maryland Heights, MO 63043 The obvious solution is to always run the generator set with an electrical load that reaches the designed operational temperature of the diesel, or
314.739.8700 approximately 75% of full load. Built-up fuel deposits and carbon can be removed by running the diesel engine at the required operational temperature
for several hours if wet stacking has not yet reached the level where carbon buildup can only be removed by a major engine overhaul. The following load
bank solutions should prevent a reoccurrence of wet stacking.
Austin Automatic auxiliary loading:
4918 Burleson Road When the generator set is the only source of power and the connected load for periods is very light a auxiliary load bank. The auxiliary automatically
Austin, TX 78744
512.477.6937 switches on when it detects the facility load is too low to adequately load the generator. When the facility load increases the load bank will switch off.
Facility manual load bank:
Operated as described for the automatic load bank, but a manually operated system for use with light loads and when the larger load is also manually
initiated. The load bank can also be used for load testing a system primarily used for standby power.
Dallas/Ft. Worth
2916 National Drive Portable load bank: The distributor for the diesel generator set is often the best qualified to undertake the maintenance of the system. Today it is
Garland, TX 75041 very common for the owner of a standby generator system to outsource complete maintenance of the system and have a planned maintenance (PM)
972.265.0768 contract with a full service generator-set supplier.
101 Industrial Boulevard During a regularly scheduled planned maintenance call, the distributor will bring in a portable load bank to run the generator at a load that maintains
Mansfield, TX 76063 the designed operational temperature. Portable load banks range from a few 10kW thru 2MW units mounted on large trailers as pictured.
817.640.5544 5.0 Note regarding - Joint Commission of Accreditation for Hospital Organizations (JCAHO)
We feel it of interest to note that many hospitals are now being accredited
by the Joint Commission. This organization addresses emergency
Longview management of hospitals (such as occurs with loss of utility power, water,
1913 East US Hwy 80
White Oak, TX 75693
etc). They provide standards covering: provisioning of care, treatment and
903.291.8305 services, patients rights and responsibilities in hospitals, and this includes
a reliable EPSS in most cases. There has to be a written emergency plan
in place with clearly defined responsibilities and assignation of adequate
staff, including multiple back-up personnel.
San Antonio
5803 Rocky Point All such persons must be trained and their attendance should be taken
San Antonio, TX 78249 into account by the EPSS supplier when arranging such courses. The
210.333.0377 EPSS maintenance requirements must conform to NFPA 110 for testing
purposes, but in addition, calls for monthly testing of generator and
automatic transfer switches.
More details can be found on JCAHO web site:
www.jointcommission.org
This poor combustion leads to soot formation and unburned fuel residues which clogs and
gums piston rings. This causes a further drop in sealing e ciency and exacerbates the initial
low pressure. Glazing occurs when hot combustion gases blow past the now poorly sealing
piston rings, causing the lubricating oil on the cylinder walls to ' ash burn', creating an enamel-
like glaze, which smooth’s the bore and removes the e ect of the intricate pattern of honing
marks machined into the bore surface. Which are there to hold oil and return it to the
crankcase via the scraper ring.
Hard carbon also forms from poor combustion and this is highly abrasive and scrapes the
honing marks on the bores leading to bore polishing, which then leads to increased oil
consumption (blue smoking) and yet further loss of pressure, since the oil lm trapped in the
honing marks is intended to maintain the piston seal and pressures. Un-burnt fuel leaks past
the piston rings and contaminates the lubricating oil. Poor combustion causes the injectors to
become clogged with soot, causing further deterioration in combustion and black smoking.
The problem is increased further the formation of acids in the engine oil caused by condensed
water and combustion by-products which would normally boil o at higher temperatures. This
acidic buildup in the lubricating oil causes slow but ultimately damaging wear to bearing
surfaces.
https://www.auroragenerators.com/blogs/generators/119916609-what-happens-to-engines-running-without-sufficient-loads 2/5
24/1/2018 What Happens to Engines Running Without Sufficient Loads
This cycle of degradation means that the engine soon becomes irreversibly damaged and may
not start at all and will no longer be able to reach full power when required. Under loaded
running inevitably causes not only white smoke from unburnt fuel but over time is joined by the
blue smoke of burnt lubricating oil leaking past the damaged piston rings and the black smoke
caused by the damaged injectors. This pollution is unacceptable to the authorities and any
neighbors.
Once glazing or carbon buildup has occurred, it can only be cured by stripping down the engine
and re-boring the cylinder bores, machining new honing marks and stripping, cleaning and de-
coking combustion chambers, fuel injector nozzles and valves. If detected in the early stages,
running an engine at maximum load to raise the internal pressures and temperatures, allows
the piston rings to scrape glaze o the bores and allow carbon buildup to be burnt o .
However, if glazing has progressed to the stage where the piston rings have seized into their
grooves, this will not have any e ect.
The situation can be prevented by carefully selecting the generator set in accordance with
manufacturers printed guidelines.
For emergency only sets, which are islands, the emergency load is often only about 1/4 of the
sets standby rating, this apparent oversize being necessitated to be able to meet starting loads
and minimizing starting voltage drop. Hence, the available load is not usually enough for load
testing and again engine damage will result if this is used as the weekly or monthly load test.
This situation can be dealt with by hiring in a load bank for regular testing or, installing a
permanent load bank. Both these options cost money in terms of engine wear and fuel use but
are better than the alternative of under loading the engine.
https://www.auroragenerators.com/blogs/generators/119916609-what-happens-to-engines-running-without-sufficient-loads 3/5
THE IMPACT OF
GENERATOR SET
UNDERLOADING
Brian Jabeck
Market Development and Design Engineer Consultant
Electric Power Division
October 2014
THE IMPACT OF GENERATOR SET UNDERLOADING
INTRODUCTION
System health and reliability are critical to backup and prime systems are designed with common goals: providing reliable power
power solutions for every facility, from mission critical data centers and maximizing system efficiency. To achieve these design goals,
to neighborhood grocery stores. A generator set is a key piece it is important to understand system operation, load profile and
of the power system, and proper operation and maintenance are schemes, and required maintenance. This paper will focus on the
essential to long-term system reliability that ensures availability operation of generator sets in low-load scenarios and what can
and uptime. result if they are used outside of these parameters.
While power systems vary in operation, application and load
profile depending on the purpose and complexity, all power
AFTERTREATMENT
Aftertreatment components such as diesel oxidation catalysts Meeting the minimum temperature is also critical in applications
(DOC), selective catalytic reduction (SCR) components and diesel with an SCR system. If the SCR system does not reach the
particulate filters (DPF) are commonplace in many locations and minimum operating temperature, the system will not begin dosing
applications, and they are all impacted by low-load operation. diesel exhaust fluid (DEF) into the exhaust stream, causing higher
Without proper design and planning, low-load operation will have than expected emissions levels and impacting federal or local
an impact on all aftertreatment components, causing emissions site permits.
targets to be missed and ultimately leading to engine shutdown. Some SRC systems may need to be equipped with an additional
A DOC or DPF that is operating below the minimum exhaust tem- exhaust heater to help meet minimum exhaust temperature
perature can cause back pressure limits to reach critical levels in a requirements. While this may help maintain temperature needs,
short period of time and lead to generator set shutdown. This issue it also requires additional load to operate, which increases system
becomes more critical in distributed or modular systems where complexity, cost and maintenance, and it does not address the
there is no paralleling capability to share load between multiple impact of underloading on the engine. A more effective approach is
units and ensure that a generator set is not operating at low loads to ensure that each generator set meets its minimum load targets
for extended periods of time. for improved long-term system reliability and durability.
3
THE IMPACT OF GENERATOR SET UNDERLOADING
If maintained properly, diesel and gas generator sets can operate Caterpillar recommends a testing process for diesel and natural
at light loads for long periods of time with no harmful effects. After gas generator sets. For diesel generator sets, Caterpillar recom-
operation at low load levels, each impacted generator set should mends loading the generator set to a minimum of 30 percent load
operate under increased load to raise the cylinder temperature and for approximately 30 minutes for every four hours of light load
pressure, which cleans the deposits from the combustion chamber. operation. Exhaust temperature measurements should be taken
In addition, if low load operation is expected to occur regularly, a at the exhaust manifold prior to the turbo or in the exhaust stack
more aggressive maintenance plan will help to ensure that there just after the turbo to confirm that the recommended exhaust
is no excessive component wear and the chances for unplanned temperatures are met during operation.
downtime are minimized. The requirements for natural gas generator sets are slightly
The first major consideration in managing low load is how to different. First, Caterpillar recommends aggressively working to
add load to a system if the building load is not enough, or if the limit underloading natural gas generator sets. See Table 1 below
customer does not want to use critical loads for generator set for time limits on low load operation for natural gas engines. After
maintenance. This issue can be resolved by having access to the time limit for reduced load operation has expired, the engine
installed system load banks or a quick connect system that will should be operated for a minimum of two hours at a load factor of
allow for load banks to be easily tied into the power system at least 70 percent. Following these guidelines will keep engine
for testing or maintenance purposes. Accounting for these maintenance to a minimum and improve long-term product health
requirements during the design phase allows for seamless and durability.
integration into the system, which can be more cost effective For more information on generator set maintenance and testing,
than having to retrofit a site after construction and installation please contact your local Cat dealer or reference the operation
are complete. and maintenance manual.
Table 1: Time limits for low load operation of natural gas generator sets.
4
THE IMPACT OF GENERATOR SET UNDERLOADING
CONCLUSION
Underloading your power system impacts many individual prevalent in the power generation market, specifically in the
components as well as overall system performance. While the standby market. To help minimize the effects of underloading,
simple solution is ensuring that your operational load is above it is critical to have operation and maintenance plans in place
50 percent of the generator set nameplate, actual site conditions, to maintain the health and reliability of the complete system
site requirements and site expansion do not always line up with and your generator set.
initial system design plans. This makes system underloading
ABOUT
About Caterpillar
For nearly 90 years, Caterpillar Inc. has been making sustainable progress possible and driving positive change on every continent.
Customers turn to Caterpillar to help them develop infrastructure, energy and natural resource assets. With 2013 sales and
revenues of $55.656 billion, Caterpillar is the world’s leading manufacturer of construction and mining equipment, diesel and
natural gas engines, industrial gas turbines and diesel-electric locomotives. The company principally operates through its three
product segments – Resource Industries, Construction Industries and Power Systems – and also provides financing and related
services through its Financial Products segment. For more information, visit caterpillar.com. To connect with us on social media,
visit caterpillar.com/social-media.
© 2014 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, BUILT FOR IT, their respective logos,
“Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used without permission.
5
ANEXO D – DIAGRAMA UNILINEAL ELÉCTRICO
B
C
1 POWER HOUSE 11
VIEW ROOF
9 POWER HOUSE 21
VIEW WITHOUT ROOF
7 4 6463250.84 265742.60 - D
Area (m2) 20.000 (2 Hectares)
LEGEND
ITEM DESCRIPTION
POWER HOUSE 12 POWER HOUSE 22 1 POWERHOUSE
VIEW ROOF VIEW WITHOUT ROOF
16 7 SPILL TANK
8 DAILY DIESEL TANK
18 19
20 14 9 FUEL OIL COOLERS
10 10 DIESEL STORAGE TANKS
21
17 13 11 FUEL TANK AREA
12 UNLOADING & PUMPING STATION
IMPORTANT NOTE:
DRAWING PRELIMINARY, CHANGES AND MODIFICATIONS MAY ARISE
DURING DETAIL ENGINEERING PHASE
FORMAT SCALE
A-0 1:400
CLIENT:
CLIENT Nr.
- - - - - -
LAYOUT DRAWING - -
- - - - - - GENERAL PLAN VIEW
- SHEET 1 TO 1 PROJECT Nr -
THE INFORMATION CONTAINED IN THIS DOCUMENT IS CONFIDENTIAL AND RESTRICTED, AND IS TO BE USED ONLY FOR THE PURPOSES ESTABLISHED IN THE DOCUMENT.
00 FOR INFORMATION EGM RAG JQV 28-03-18 NO MODIFICATION, EXPLOTATION, REPRODUCTION, COMMUNICATION TO ANY THIRD PARTY, DISSEMINATION OR DISTRIBUTION OF THE WHOLE OR ANY PART OF THE DOCUMENT
IS PERMITTED WITHOUT THE PRIOR, WRITTEN CONSENT OF TSK FAILURE TO RESPOND TO ANY REQUEST FOR SUCH CONSENT SHALL IN NO WAY BE CONSTRUED AS AUTHORIZATION FOR USE.
REV. DESCRIPTION DRAWN CHECKED APPROVED DATE
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