Electric Power Ratings Guide: Generator Sets
Electric Power Ratings Guide: Generator Sets
Electric Power Ratings Guide: Generator Sets
Generator Sets
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CONTENTS
RATINGS GUIDE
Cat Diesel Generator Sets 50 Hz Ratings 60 Hz Ratings Rental Power Ratings Definition of Diesel Ratings 50 Hz Ratings 60 Hz Ratings Definition of Gas Ratings 4 6 9 10 14 15 17 20 24 28 39 40
EMCP 4 Systems Products Conversion Tables Product Support Definitions Product Support Customer Support Agreements
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DIESEL
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DIESEL 50 H
Z
Configuration Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC, Low Emissions Low BSFC Low BSFC Low BSFC, Low Emissions Low BSFC, Low Emissions Low BSFC, Low Emissions Low BSFC, Low Emissions Low BSFC Low BSFC, Low Emissions Low BSFC, Low Emissions Low BSFC Low BSFC Low BSFC
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DIESEL 50 H
Z
Configuration Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC Low BSFC
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DIESEL 60 H
Z
ekW Standby 40 50 60 80 100 40 50 60 80 100 125 150 175 Prime 36 45 55 72 90 36 45 55 72 90 114 136 158
Engine
Configuration ESE ESE ESE ESE ESE ESE ESE ESE ESE ESE ESE ESE ESE
Single Phase Output* 1800 rpm D40S C4.4 D50S C4.4 D60S C4.4 D80S C4.4 D100S C4.4 Three Phase Output** 1800 rpm D40 C4.4 D50 C4.4 D60 C4.4 D80 C4.4 D100 C4.4 D125 C6.6 D150 C6.6 D175 C6.6
*All ratings at 1.0 pf **All ratings at 0.8 pf (ESE) EPA Emergency Stationary Exempt
Configuration
(ES (ES *R
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DIESEL 60 H
Z
Configuration ESE Low BSFC Low BSFC ESE, Low BSFC Low BSFC Low BSFC Low BSFC ESE, Low BSFC ESE, Low BSFC EPA Tier 4 Interim, ESE, Low BSFC ESE, Low BSFC ESE, Low BSFC ESE, Low BSFC Low BSFC Low BSFC ESE, Low BSFC Low BSFC EPA Tier 4 Interim, ESE, Low BSFC Low BSFC ESE, Low BSFC Low BSFC Low BSFC Low BSFC, Low Emissions Low BSFC, Low Emissions ESE Low BSFC Low BSFC, Low Emissions EPA T4, ESE Low BSFC EPA T4, ESE EPA Tier 4 Interim, ESE, Low BSFC EPA Tier 4 Interim, ESE, Low BSFC ESE, Low BSFC
(ESE) EPA Emergency Stationary Exempt (ESP) Emergency Standby Rating *Rating does not include package mounted radiator
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DIESEL 60 H
Z
Configuration
*Su
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DIESEL
Configuration
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DIESEL
RATINGS DEFINITIONS
Emergency Standby Power (ESP) Output available with varying load for the duration of an emergency outage. Average power output is 70% of the emergency standby power rating. Typical operation is 50 hours per year with maximum expected usage of 200 hours per year.
Standby Power Output available with varying load for the duration of the interruption of the normal source power. Average power output is 70% of the standby power rating. Typical operation is 200 hours per year, with maximum expected usage of 500 hours per year.
Mission Critical Standby Power 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.
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RATINGS DEFINITIONS
DIESEL
Prime Power Output available with varying load for an unlimited time. Average power output is 70% of the prime power rating. Typical peak demand of 100% of prime-rated ekW with 10% of overload capability for emergency use for a maximum of 1 hour in 12. Overload operation cannot exceed 25 hours per year.
Load Management Output available with varying load for maximum 500 hours a year. Average power output is 100% of the prime power rating. Typicalpeak demand of 100% of prime-rated ekW. Overload operation not available.
Continuous Power Output available without varying load for an unlimited time. Averagepower output is 70 100% of the continuous power rating. Typical peak demand is 100% of continuous rated ekW for 100% of operating hours.
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GAS 50 H
Z
Ra Na Bio
NA TA All
Ratings at ISO 3046-1 conditions. SCAC Temp = 40-53 C (104-127 F). PF = 1.0. Natural Gas at 35.6 MJ/Nm3 (905 Btu/ft3), MN = 80. Biogas (Landfill, Sewage, Digester Gas) at 18.0-23.6 MJ/Nm3 (457-600 Btu/ft3) and MN = 130-134.
NA = Naturally Aspirated, Stoichiometric Engine: *Catalyst Rating Availability TA = Turbocharged & Aftercooled, Stoichiometric Engine: *Catalyst Rating Availability All other engines: Lean Burn
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GAS 60 H
Z
Ratings at ISO 3046-1 conditions. SCAC Temp = 53 C (127 F). Standby ratings at PF = 0.8. Natural Gas at 35.6 MJ/Nm3 (905 Btu/ft3), MN = 80. Contact dealer for LPG or Propane ratings. Biogas (Landfill, Sewage, Digester Gas) at 18.0-23.6 MJ/Nm3 (457-600 Btu/ft3) and MN = 130-134. NA = Naturally Aspirated, Stoichiometric Engine: *Catalyst Rating Availability TA = Turbocharged & Aftercooled, Stoichiometric Engine: *Catalyst Rating Availability All other engines: Lean Burn
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GAS 60 H
Z
Ratings at ISO 3046-1 conditions. SCAC Temp = 40-53 C (104-127 F). PF = 1.0. Natural Gas at 35.6 MJ/Nm3 (905 Btu/ft3), MN = 80. Biogas (Landfill, Sewage, Digester Gas) at 18.0-23.6 MJ/Nm3 (457-600 Btu/ft3) and MN = 130-134.
NA = Naturally Aspirated, Stoichiometric Engine: *Catalyst Rating Availability TA = Turbocharged & Aftercooled, Stoichiometric Engine: *Catalyst Rating Availability All other engines: Lean Burn
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RATINGS DEFINITIONS
GAS
Standby Power Output available with varying load for the duration of the interruption of the normal source power. Average power output is 70% of the standby power rating. Typical operation is 200 hours per year, with maximum expected usage of 500 hours per year. Fuel stop power in accordance with ISO 3046-1.
Continuous Power Output available without varying load for an unlimited time. Averagepower output is 70-100% of the continuous power rating. Typical peak demand is 100% of continuous rated ekW for 100% of operating hours. Continuous power is in accordance with ISO 8528-1. Fuel stop power in accordance with ISO 3046-1.
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EMCP 4
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EMCP 4
CAT EMCP 4
EMCP 4.1 The EMCP 4.1 provides basic engine controls stop/run/auto push button controls, cycle crank, and cool down timer. The 3.8 inch graphical display supports multiple languages, including character languages such as Chinese, Arabic, Russian, and Japanese. The EMCP 4.1 provides monitoring of generator electrical output, including AC voltage, current, and frequency, and mechanical information such as oil pressure, oil temperature, coolant temperature, engine speed, and battery voltage. It also provides a number of protective functions, such as warnings and shutdowns for over/under voltage, over/under frequency, low oil pressure, high coolant temperature, low coolant level, failure to start, and overspeed. EMCP 4.2 The EMCP 4.2 builds on the features of the EMCP 4.1 controller, offering expanded generator set protection and monitoring, such asgenerator kW, kVA, and kW-hr. Flexibility is also increased with the addition of a modbus RTU communication port, remote annunciator modules, and expansion I/Omodules to allow the EMCP 4 system to be configured to meet sitespecific design requirements. With the additional monitoring and expansion modules available, theEMCP 4.2 is designed to provide control and protection for critical installations, such as NFPA-110 Level 1 applications.
With t integr
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EMCP 4
EMCP 4.3 The EMCP 4.3 further expands the EMCP 4 product line with the addition of 5.5inch graphical display and additional context specific navigation keys. With the addition of a modbus TCP port, the EMCP 4.3 controller can be easily integrated into complex systems requiring complete generator set monitoring. EMCP 4.4 The EMCP 4.4 builds on the EMCP 4.3 functionality with the addition of fully automatic multi generator set paralleling. The EMCP 4.4 provides all of the functions required to automatically parallel generator sets, including dead busarbitration, automatic or manual modes of operation, and load sharing (real and reactive). The EMCP 4.4 can also be configured to automatically cycle generator sets on line and off line based on the site load.
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SYSTEMS PRODUCTS
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SYSTEMS PRODUCTS
Paralleling Switchgear 50 Hz & 60 Hz Fully customizable Breaker Based 220V to 27 kV Color Touchscreen (HMI) Controls Typical applications: Emergency Standby Utility Paralleling Load Management Prime Power EPIC (Engine Paralleling and Integration Control) Generator Set Paralleling Controls (customer supplied electrically operated breaker) Color Touchscreen (HMI) Controls Field expandable Typical applications: Emergency Standby Utility Paralleling Load Management XLM1 (Emergency Transfer and Load Management) Parallels a single genset to a single utility Customer Configured Color Touchscreen (HMI) Controls Typical applications: Emergency Standby Utility Paralleling Load Management
Op
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SYSTEMS PRODUCTS
UPS 50 Hz
Output kVA 60-120 160-500 250 250-500 650 750-1000 Parallel Capable Y Y N Y Y Y UPS Model UPSB125 UPSB505 UPS250i UPS500iG UPS750 UPS1000iZ UPS Type Double Conversion Double Conversion Line Interactive Line Interactive Line Interactive Line Interactive Energy Storage Battery Battery Flywheel Flywheel Flywheel Flywheel
60 Hz
Output kVA 40-130 150-225 300-500 555-1100 300 300-600 750 900-1200 Parallel Capable Y Y Y Y N Y Y Y UPS Model UPSB130 UPSB220 UPSB500 UPSB1100 UPS300 UPS600G UPS750 UPS1200Z UPS Type Double Conversion Double Conversion Double Conversion Double Conversion Line Interactive Line Interactive Line Interactive Line Interactive Energy Storage Battery Battery Battery Battery Flywheel Flywheel Flywheel Flywheel
ATS
Amp Rating 40-4000 40-1200 30-1000 200-5000
Operating Modes: Open Transition Closed Transition Delayed Transition Bypass Isolation
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CONVERSIONS
RATINGS GUIDE
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CONVERSIONS
FUEL SYSTEM DIESEL
Day Tank Sizing
Tank Size (gal) = Rated BSFC (lb/hp hr) x Rated HP x Load Factor 7.076 (lb/gal) x Hours Between Refilling + Reserve Requirement OR
r k
Note: Additional tank capacity required for cooling of recirculated fuel in unit-injected engines. Tank should be located below level of injectors or nozzles.
Based on 100,000 sq ft. of office bldg., etc and 40N. Latitudes Air Conditioning and Compressor 400 tons prime load Use two 200 hp engines (No Standby)
Refrigeration
One ton refrigeration = 200 Btu/min = 12,000 Btu/h One Boiler hp = 33,475 Btu/h One ton compressor rating = One engine hp Auxiliary air conditioning equipment requires 1/4 hp/ton of compressor rating Complete power requires 4-5 hp per daily ton capacity hp = 1/4 x cu ft m/min at 100 psi Increase bhp 10% for 125 psi Decrease bhp 10% for 80 psi
Ice Plant
Air Compressor
ELE
28
V Ic kW kVA HP RPM
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CONVERSIONS
ELECTRICAL TABLES
Alternating Current Single-Phase Three-Phase V x I x P.F. 1000 VxI 1000 kW .746 x EFF. (Gen) HP x .746 EFF. (Mot.) HP x .746 V x P.F. x EFF. kW x 1000 V x P.F. kVA x 1000 V Poles x RPM 120 V x I x 1-(P.F.)2 1000 100 (VNL-VFL) VFL 1.732 x V x I x P.F. 1000 1.732 x V x I 1000 kW .746 x EFF. (Gen) HP x .746 EFF. (Mot.) HP x .746 1.732 x V x EFF. x P.F. kW x 1000 1.732 x V x P.F. kVA x 1000 1.732 x V Poles x RPM 120 1.732 x V x I x 1-(P.F.)2 1000 100 (VNL-VFL) VFL 100 (VNL-VFL) VFL kW .746 x EFF. (Gen) HP x .746 EFF. (Mot.) HP x .746 V x EFF. kW x 1000 V
To Obtain kW kVA Horsepower required when kW known (Generator) kW input when HP known (Motor) Ampheres when HP known Ampheres when kW known Ampheres when kVA known Frequency Hz Reactive kVA (kVAr) % Voltage Regulation
ELECTRICAL TABLE ABBREVIATIONS: V voltage in volts I current in ampheres kW power in kilowatts (actual power) kVA kilovolt-ampheres (apparent power) HP horsepower RPM revolutions per minute kVAr reactive kilovolt-ampheres EFF. efficiency as a decimal factor NL no load FL full load P.F. power factor Note: DC kW = DC kVA
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CONVERSIONS
THREE-PHASE CONNECTION SYSTEMS
Typ
Full V
Auto
Part spee 7 8
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CONVERSIONS
REDUCED VOLTAGE STARTERS
Line Current (% Full Voltage) Starting Current 100 68 46 30 Starting Torque (% of Full Voltage) Starting Torque 100 64 42 25
Type of Starter Full Voltage Starter Auto Transformer 80% Tap 65% Tap 50% Tap Resistor Starter Single Step (adjusted for motor voltage to be 80% of line voltage) Reactor 50% Tap 45% Tap 37.5% Tap Part Winding (lowspeed motors only) 75% Winding 80% Winding
80
80
64
50 45 37.5
50 45 37.5
25 20 14
100 100
75 50
75 50
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CONVERSIONS
COMPARISON OF REDUCED VOLTAGE STARTING METHODS
Two-Step Part Winding
Characteristic Starting Line Current at Same Motor Terminal Voltage Starting Power Factor Power Draw from Line During Starting Torque
Autotransformer Least
Primary Resistor
Reactor
Low Low Increases slightly with speed Motor momentarily disconnected from line from start to run Average
High*
Low
Low
Increases rapidly with speed Smooth. Transfer made with little change in motor terminal voltage Lower in small size- Average otherwise equal Same Same Same Same
Less than others No provision for adjustment of starting current Less than others More than others
Same Same
* Resistor starting adds considerable kW load to generator set. Total power required includes the motor kW and the kW which is lost as heat in the resistor. The series resistors account for a higher than normal starting power factor.
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CONVERSIONS
ENGINE ROOM VENTILATION
DS
Step nding
slightly peed
oth
others Engine room ventilation can be estimated by the following formulas, assuming 100 F (38 C) ambient air temperature: V (cfm) = H + Engine Combustion Air 0.070 x 0.24 x T H + Engine Combustion Air 1.099 x 0.017 x T
n others
V (m3/min) =
V = Ventilation air (cfm) (m3/min). H = Heat radiation (Btu/min) (kW). T = Permissible temperature rise in engine room (F) (C). Density of air at 100 F = 0.070 lb/cu ft (1.099 kg/m3). Specific heat of air = 0.24 Btu/F (0.017 kW/C).
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CONVERSIONS
CONVERSION FACTORS
Length
Unit mm in ft yd m km mi mm 1 25.4 304.8 914.4 1000 1000000 1609344 in 0.03937 1 12 36 39.3701 39370.1 63360 ft 0.003281 0.08333 1 3 3.28084 3280.84 5280 yd 0.001094 0.02778 0.33333 1 1.09361 1093.61 1760 m 0.001 0.0254 0.3048 0.9144 1 1000 1609.34 km 0.000001 0.000025 0.000305 0.000914 0.001 1 1.60934 mi 0.00062 0.62137 1
1m
Area
Unit mm in m ft 1 sq mile = 640 acres 1 acre = 4840 yd2 mm 1 645.16 1000000 92903 in 0.00155 1 1550 144 m 0.000645 1 0.0929 ft 0.006944 10.76391 1 1 cir mil = 5.067 x 10-6cm2
MCFD
Weight
Unit Kilograms Ounces Avoirdupois Pounds Avoirdupois Short Ton Long Ton Metric Ton Kilograms 1 0.02835 0.45359 907.185 1016.05 1000 Ounces Avoirdupois 35.274 1 16 32000 35840 35274 Pounds Avoirdupois 2.2046 0.0625 1 2000 2240 2204.62 Tons Short 1 1.12 1.1023 Long 0.8929 1 0.9842 Metric 0.9072 1.0160 1
C Foo J Kilo T
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CONVERSIONS
CONVERSION FACTORS
mi 0.00062 0.62137 1
Flow
Unit U.S. gpm 1 million gal/day ft/s m/h L/s MCFD = 1000 ft3/day U.S. gal/min 1 694.5 448.8 4.403 15.85 million U.S. gal/day 0.001440 1 0.0646 0.00634 0.0228 ft/s 0.00223 1.547 1 0.00981 0.0353 m/h 0.2270 157.73 101.9 1 3.60 L/s 0.0631 43.8 28.32 0.2778 1
Energy
Unit BTU Calorie Foot-Pound Joule Kilocalorie Therm BTU 1 0.00397 0.001285 0.000948 3.96825 100000 Cal 252 1 0.323765 0.23895 1000 396.8254 ft-lb 778 3.08866 1 0.73745 3089 128.5347 J 1055.056 4.187 1.356 1 4185 94.78169 Kcal 0.252 0.001 0.003089 0.000239 1 0.39682 Therm 0.00001 2.519 1
-6cm2
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CONVERSIONS
CONVERSION FACTORS
Volume and Capacity Volume and Capacity
Unit in ft yd mm m U.S.gal lmp gal liter acre-ft in 1 1728 46656 6.1 x 10-5 61023.7 231 277.419 61.0237 ft 0.00058 1 27 4.0 x 10-8 35.3147 0.13368 0.16054 0.03531 43560 1 bushel = 1.244 ft3 yd 0.00002 0.03704 1 1.30795 0.00495 0.00595 0.00131 1613.33 mm 16387.1 28320000 764554858 1 1000000000 3785420 4540090 1000000
1 bushel = 4 pecks
Power
Unit Btu/min ft-lb/min Horsepower Joules/min Metric hp Kilowatt Watt Btu/min 1 0.00128 42.456 0.00095 41.827 59 0.05687 ft-lb/min 778.2 1 33000 0.7405 32550 44250 44.25 hp 0.02358 0.00003 1 0.0000223 0.98632 1.34102 0.00134
J 10 1 4
4 5 59
14 14 0.1
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CONVERSIONS
CONVERSION FACTORS
U.S. gal 0.00432 7.48052 201.974 2.6 x 10-7 264.192 1 1.20095 0.26417 325851
lmp gal 0.00361 5.22883 168.178 2.2 x 10-7 219.969 1 0.21997 271335
F) 464 34 333
2O
Atmospheres
09 84 49 486
101.4Pa (14.7 psi) 0.001315 0.03342 0.00246 0.02950 0.06805 0.96784 0.98692 0.00986920
kPa
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CONVERSIONS
CONVERSION FACTORS
Temperature Conversion
F = (1.8 x C) + 32 C = 0.5555 (F 32)
1 quadrant = 90 degrees 1 quadrant = 1.57 radians 1 radian = 57.3 degrees 1 degree = 60 minutes 1 minute = 2.9 x 10 radians
Angle
Identifying Code Letters on AC Motors NEMA Code Letter A B C D E F G H J K L M N P R S T U V Starting skVA/hp 0.00 3.14 3.15 3.54 3.55 3.99 4.00 4.49 4.50 4.99 5.00 5.59 5.60 6.29 6.30 7.09 7.10 7.99 8.00 8.99 9.00 9.99 10.00 11.19 11.20 12.49 12.50 13.99 14.00 15.99 16.00 17.99 18.00 19.99 20.00 22.39 22.40
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PRODUCT SUPPORT
PRODUCT SUPPORT DEFINITIONS
Extended Service Coverage (ESC) Depending on the model and application, Silver, Gold, Platinum and Platinum Plus coverage levels are available from Caterpillar with terms to meet most applications, whether prime or standby. Platinum and Platinum Plus provide additional allowances for overtime emergency freight, rental, crane and rigging support. Please see the registration contract for details. Equipment New Product Existing Product Overhauls Coverage Option New ESC Advantage ESC OPC*
Electric Power ESC reimburses covered parts at customer list price, labor at selling rates and travel and mileage charges (less any deductibles) for covered repairs. Available worldwide for all Cat Electric Power Products, ESC provides usual and customary parts and labor costs for covered system failures due to defects in materials and workmanship on components over the duration of the covered period.
This is a brief description of Extended Coverage. See your Cat dealer for more information. The Extended Coverage contract will govern.
*Overhaul Protection Coverage
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PRODUCT SUPPORT
CUSTOMER SUPPORT AGREEMENTS
A Customer Support Agreement (CSA) is an arrangement between the end user and the Cat dealer that helps lower the cost per unit of production. Agreements are tailored to fit your business needs and can range from simple Preventive Maintenance Kits to sophisticated Total Cost Performance Guarantees. Qualified Factory Trained dealer technicians assist you by maintaining your Cat Electric Power Products and driving downoperating costs. Perhaps the most important feature ofany CSA is flexibility. A Preventive Maintenance (PM) agreement covers specified maintenance at a fixed cost. You maintain reliability and efficiency because the maintenance is performed by highly skilled technicians at guaranteed costs, giving you the ability tobudget more accurately. A Total Maintenance and Repair (TM&R) agreement covers all of the maintenance and repair costs. Instead of paying for maintenance or repairs as they are needed, you pay one flat rate to cover a broad range of parts and services.
Deta by hi tech
Sche main
Labo
Use parts
SOS inter
Com
Check with your local Cat dealer for available options with each agreement.
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PRODUCT SUPPORT
CUSTOMER SUPPORT AGREEMENTS
PM Detailed inspections by highly skilled technicians Scheduled maintenance Labor and travel costs Use of genuine Cat parts, fluids and filters SOSSM Services and interpretation Component repairs All unscheduled repairs, including wear out, with no exclusions, limitations or deductibles
TM&R
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LEXE7582-05
June 2013 2013 Caterpillar All Rights Reserved Printed in USA CAT, CATERPILLAR, their respective logos, CaterpillarYellow 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.
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