Diesel Generator Plant Design

Technical Seminar 2017 - Lagos
Power Generation Design Awareness
By JMG Power Generation

Topics
1) Understanding the Generator set Rating
2) Gen-set De-rate Verification / Calculation
3) Gen-set Sizing Consideration
4) Generator Installation Design Consideration
a) Installation Layout Consideration

b) Ventilation System
c) Fuel System
d) Exhaust System
e) Cooling System
f) Noise Control
g) Vibration Control
5) Paralleling Basic and Myths , Generator Set Controls
6) Master Control System & Remote Monitoring

2 JMG Ltd Confidential
Understanding the Generator set Rating

Definitions
Three Definitions
• Continuous Operating Power (COP)
• Prime Power (PRP)
• Emergency Standby power (ESP)
ISO 8528 Part 1 defines these ratings

• Continuous Operating Power (COP)
• Unlimited Time Prime Power (PRP)
• Limited Time Prime Power ( LTP)
• Emergency Standby power (ESP)

Rating Condition
ISO 8528 requires rating declaration at:
27 degrees Centigrade
150 metres above sea level
60% relative humidity
De-rating of the Generator might be necessary beyond
these conditions
The Power Generation Sets typically do not Derate until
40C and 1000M
Question – What causes the Derate on a Genset?

ISO 8528 Definitions
What effects your choice of Genset rating?

(COP – PRP – LTP – ESP)
• Required Running Time
• Applied load
• Ambient condition (altitude/temperature)
• Warranty
Let’s examine available ratings………

Continuous Power

Prime Power

Prime Power (Cont.)

Standby Power

Data Centre Continues (DCC)
Uptime Institute
DCC Rating :
(Uptime Institute)
Available for unlimited number
of hours in a Non –Variable
Load application during
Utility Power Failure

Rating Example on Model FG Wilson – P1500
Standby Rating 1650kVA

maximum average in a 24h period
(70%) 1155kVA
200h/year
Prime Power Rating 1500kVA

KVA
maximum average in a 24h period
(70%) 1050kVA
Limited time Prime Power 1500kVA

500h/year with non-variable load
Continuous Operating Power 1250

kVA

Generator Set Derate Verification /
Calculation

Genset Derate
What is the genset derate?

Genset Derate can be defined as environmental factors
that will reduce the rated power capability of the
Genset.
Genset Derate = Engine Derate & Alternator Derate
Two Major Factors which cause Genset Derate
• Temperature
• Altitude

Genset Derate (Cont)
Derate on a Genset is caused by:
Ambient Air Temperature – This effecting:
• Engine induction
• Engine & Radiator cooling capacity (LAT)
• Alternator temperature rise
• Circuit breaker derate
Altitude (Air Density) effecting:
• Engine induction air
• Radiator cooling capacity
• Alternator cooling capacity
Humidity
• Only naturally aspirated engines de-rate in high humidity.

Derate Calculation
The Derate Calculation is divided into two parts

• Engine Derate
• Alternator Derate
Engine and Alternator derate are calculated
separately. Both values are then compared and
available Genset Power is the lowest value
between the two.

Site Conditions:
• Genset Model or Required Power

• Duty – Standby, Prime or Continous
• Ambient Temperature
• Altitude
• Humidity
• Voltage & Frequency
Example: P400_350kVA_50C_1000M ASL_400V/50Hz

Derate Formula
Engine Derate Power =
{(Gross Engine Power x %Derate) – Fan Power} x Alt Efficiency
Alternator Derate Power =

Alternator Rated Power x Temp Derate Factor x Altitude Derate Factor



6%

 Example: Power Derate Curves
– Prime Engine Derate Power = [324.2 x (1-6%)] = 304.7kWm

 Example: Fan Power
– Fan power = 14kWm
– From Engine Derate Formula =

• [(Gross engine power x %Derate)-Fan Power] x Alt Efficiency
– Prime Engine Input Power = {[324.2 x (1-6%)]- 14kWm} = 290.7kWm

 Example: Alternator Efficiency

– Alternator Efficiency @ Prime Power = 93.4%
– From Engine Derate Formula =

• [(Gross engine power x %Derate)-Fan Power] x Alt Efficiency
– Prime Engine Power =
• {[324.2 x (1-6%)]- 14kWm} x 93.4 = 271.5kWe

26 Alternator Prime Rating

JMG LtdPower
Confidential = 320kWe
For ambient temperatures over 40°C, genset output reduces
3% derate for every 5°C above 40°C

 Alternator Prime Rating Power = 320 x 94% x100% =
300.8kWe
Alternator(LV) – Class Derate
 The letters B,F and H signifies the maximum allowable winding
temperature rise

Example: Alternator(LV) – Class Derate
 Alternator ESP power = 3200 x 0.94 x 1 = 300.8 KWe

(For class H Temperature rise)
 Alternator ESP power = 320 x 0.94 x 1 x 0.916 =275.5 KWe
(For class F Temperature rise)
 Alternator ESP power = 320 x 0.94 x 1 x 0.8 = 240 KWe
(For class B Temperature rise)

 Available Genset Power After Derate
– Prime Engine Power =

• {[324.2 x (1-6%)]- 14kWm} x 93.4 = 271.5kWe
– Alternator Prime Rating Power = 320 x 94% x100% =

300.8kWe
– Therefore the output of the genset is limited by the Engine

Power 271.5kWe / 339.4kVA (@pf 0.8
– Required Power is 350kVA
– The available power is 339.4kVA based on the stated
conditions

Topics for discussion – watch outs
 Cooling package – If the radiator’s capability is not designed for the
specified conditions, the generator set may overheat…
 Voltage levels - When the required voltage is not matching the alternator
available output then the reduced magnetic flux leads to less available
power in the alternator terminals
 Canopies, Containers - Usually higher derate due to the increased

restriction on the airflow
 Power Factor considerations - Consult the alternator operating chart –

capability curve)
 Air filters - Potential additional alternator de-rate 5-10%
 Fuel derate – Review Service bulletin 3379001 for acceptable fuel

specifications
 Circuit breaker sizing - Oversize when needed

Generator Set Sizing Consideration

Required Data for sizing
 Project requirements
– Nominal voltage, frequency
– Application (ESP,PRP,COP)
– Number of Gensets
– Climatic conditions (ambient temperature and altitude)
– Transient requirements (voltage and frequency dip requested)
– Alternator’s temp rise rating
– Maximum harmonic distortion permissible
 Load parameters
– Nature of loads – no of phases, load voltage. Special attention on non-linear
loads, regenerative loads
– Starting and running requirements (starting method used, starting and running
power factors, efficiency level, NEMA letter)
– Step sequencing

Types of Loads
 Linear Loads
– Lighting
 Non-Linear Loads
– Motors
– UPS
– Variable Frequency Drives (VFDs)
– Battery Charger loads
 Regenerative Loads
– Cranes and elevators

Types of Loads: Motors
 Starting large motors could require 6 times the running current

(DOL starting method)
 This can result in a large, sustained voltage dip
 Larger generator capacity might be required to stay within the
limit
 Reduced-voltage starter (Soft-Start) available:
– Reduces motor starting kVA
– Reduces voltage dip and generator size
– Reduces motor starting torque !

Type of Load :Regenerative Loads
 Cranes, lifts, elevators have an element of regenerative load which can be
pushed into the terminals of alternator
 Genset must have a Reverse Power detection. Dump Load to absorbs part
of the reverse power
 Rough ‘rule of thumb’ Gensets can deal with reverse power kW 10% of the
rated load

Transient performance & acceptable Voltage and Frequency dip
What is a
Voltage/Frequency dip?
The change in frequency
or voltage from its rated
value when load is
applied or removed
The recovery time is the time taken to go from a

transient state to a steady state.

ISO-8528 Performance Class
Performance Class G1 G2 G3
– Steady-state frequency band 2.5% 1.5% 0.5%

– Maximum frequency dip -15% -10% -7%
– Maximum frequency rise +18% +12% +10%
– Frequency recovery time 10 sec 5 sec 3 sec
– Steady state voltage deviation 5% 2.5% 1%
– Maximum voltage dip -25% -20% -15%
– Maximum voltage rise +35% +25% +20%
– Voltage recovery time 10 sec 6 sec 4 sec

Loading Per ISO 8528
82%
62%
38%
Break Mean Effective Pressure –BMEP (kPa)

Real world example: FG Wilson P275

ISO 8528: Performance class limits
Frequency recovery
42 JMG takes 1.6 sec
Ltd Confidential
Power Factor considerations
Lagging Power Factor Leading Power Factor
Motors - Pumps - Fans Furnaces Non-Linear filtration - lightly

- Transformers Inductance loaded UPS – Capacitor Banks
Heaters
Excitation Current ↑ Excitation Current ↓
Temperature ↑
Rotor limitation Stability – Loss of excitation
Alternator operating chart (HC6J) Engine limit
Stability limit
Generator rating – 800 kW, 1000 kVA
Rotor limit
Locus of
1000 kVA
800
800
kW
kW
Leading PF Load on Generators
– Ensure the load is always within the stability margin of the alternator
– Correct the power factor at each load wherever possible
– Interlock any PFC so that it is inoperative when the generator is the supply; or
– Interlock stages of the PFC with load components
– Do not allow a major reduction in load with the PFC still connected
– If Possible, apply lagging loads before leading
– Caution when running gensets in parallel - sometimes there
can be issues with sharing negative KVAR
30/03/2017
Oversizing Generator sets
 Operating engines at no load or loads less than 30% of
the standby power rating for prolonged periods of time
may result in:
− Wet Stacking (slobber)

− Carboning (build up of carbon on rings & injectors).
− Fuel Dilution of Lube Oil (glazing & condensation).
− Piston Detonation (localized fuel ignition)
− Excess Facility Costs, Excess Operating Costs,
Maintenance Issues
Non-linear Load Performance
 Generator should be
equipped with:
Oversizes alternator to better handle
– Low Reactance harmonics & increases reverse kVAR
capability
Alternator (< 12% sub-
transient) Oversizes alternator (similar to low reactance)
– Low Temp Rise Maintains frequency stability for sensitive loads
– Isochronous Governor Separate power source for excitation, maintains
control of excitation voltage rather than relying
– PMG Excitation on alternator output
More accurately senses the energy delivered in
– Digital 3-phase RMS the waveform in high harmonic conditions
sensing
30/03/2017
Generator Installation Design Consideration
How does it work !?
Exhaust
4. Exhaust System
Air +
2. Ventilation System
Heat
5. Cooling System
+
+ Sound
Installed Genset 6. Noise Control
Fuel
3. Fuel System 1. Layout Consideration +
Vibration
7. Vibration Isolation
2
1. Layout Consideration
Exhaust
4. Exhaust System
Air +
Heat
5. Cooling System
+
+ Sound
Fuel Installed Genset 6. Noise Control
Vibration
2
Layout Considerations
 Safety  Service Access

– Guards on potential  Connection run lengths
dangers
– Fuel lines
– Unobstructed pathways
– Electrical cabling
and service space
 Auxiliary equipment
 Ventilation
– Breather systems
– Sufficient airflow
– Aftertreatment
– Airflow path
– Source of air  Future equipment
Location Considerations…
• Consider accessibility for service
• Inspections
• Maintenance, service, & testing
• Fueling
• Monitoring
• Watch for flooding potential

• Comply with local requirements/codes.
• Ability to meet the requirements and
recommendations of Cummins application
manual
A Typical Installation inside the room…
5
Single genset Room Design (575 – 2000 KVA) with Acoustic treatment
Exhaust
4. Exhaust System
Air +
Heat
5. Cooling System
+
+ Sound
Vibration
2
GenSet Energy Balance
 Engine burns fuel and creates:
– Rotating mechanical energy/electrical power
– Heat
Exhaust 30%
Radiated Heat 10%
Cooling
Power Out 35% System
25%
Mechanical Energy
9 Fuel (BTU) In
Equipment/Room Ventilation
Radiator
Air Inlet
Louvers
Cool Air Hot Air

Flow In Flow Out
Air Outlet
Flex Duct
Louvers
Ventilation System:
Flow Through Ventilation
 Provides Combustion Air for is the Ideal Design for
Engine Proper Performance!
 Provides Cooling Air for Alternator
 Remove Room Heat
 Cools Engine block and Air for the
Radiator cooling
10
Ventilation – Importance of Good Air Flow Design
Good flow through design means the temperature
of air approaching the rear of the Genset = Ambient
temperature.
Anything other than proper flow-through design…
Air temp will be higher & effects Cooling System performance
Proper Flow-
Through Design
50C 50C
122F
= 122F
11
Gensets With Mounted Radiators
• Air Flow fixed by Genset design (Radiator)
• Other heat sources in the room must be considered
• Design the room ventilation within specified limits
 Genset Air flow
 Maximum Restriction
Rule of Thumb:
• Always insulate indoor exhaust systems
• Effective open area for radiator
exhaust air should be should be
roughly equal to radiator area.“
Effective open area ” means all restriction
to flow must be taken into account.
• Effective open area of inlet to room
must be 1½ times the radiator area
Temperature Rise Across System
There is significant temperature rise in air as it

moves through the system.
Result of poor design is inability to carry full load at high
ambient temperature conditions.
40 C
50 C
104 F
122 F
15
Specifying Airflow Requirements
a) Determine heat rejection to ambient room (Qtotal)
i. Include engine, alternator, muffler, exhaust piping, auxiliary items.
b) Spec max. allowable temperature rise
i. ∆𝑇𝑚𝑎𝑥 = 𝑀𝑎𝑥. 𝑅𝑜𝑜𝑚𝑇𝑒𝑚𝑝. −𝑀𝑎𝑥. 𝐴𝑚𝑏𝑖𝑒𝑛𝑡𝑇𝑒𝑚𝑝.
c) Calculate cooling airflow required (Qroom)
𝑄𝑡𝑜𝑡𝑎𝑙
i. 𝑄𝑟𝑜𝑜𝑚 = 𝐶
𝑝 ×∆𝑇𝑚𝑎𝑥 ×𝑑
d) Calculate total room airflow requirement (Qroom)

i. 𝑄𝑡𝑜𝑡𝑎𝑙 = 𝑄𝑟𝑜𝑜𝑚 + 𝑄𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛
e) In case of need to compensate for density changes due to altitude
i. For every 305 meters increase air flow by 3%
f) Compare to radiator airflow (when applicable)
Qroom= minimum forced ventilation airflow (m3/min)

Qtotal= total heat emitted to room (MJ/min)
Cp=specific heat (1.01x10-3 MJ/kg/oC)
∆T=Generator set room temperature rise (oC)
d=density of air (1.20 kg/m3)
Shutdown Ventilation Considerations
Engine rejects significant heat immediately after
stopping
Auxiliary ventilation highly desirable
16
Ventilation Systems Summary
Check for:
• Sufficient inlet and exhaust opening size

• “Straight Line” design
• Possibility of a “short circuit”
• Other heat sources in room (e.g., uninsulated exhaust, boilers )
• Where you dump ventilation air
• Prevailing wind direction (barriers needed?)
• Clean air intake (notably alternator air)
Different Engines = Different requirement

 More KW = More air flow
 Exhaust emission requirements usually result in more heat
rejection to cooling system.
3. Fuel System
Exhaust
4. Exhaust System
Air +
Heat
5. Cooling System
+
+ Sound
Fuel +
3. Fuel System 1. Layout Consideration
Vibration
2
Diesel Fuel Systems
 Reliable fuel supply depends on:
– No air in fuel
– No particles in fuel
– Fuel temperature
– Proper volume delivered to engine
– Fuel quality
 Items affected by local codes and interpretation
– Tank size & type
– Containment & fill provisions
– Venting (tank, spill containment, room)
– Sensors & alarms
Requirements for Fuel Systems
 Piping type - black iron

 Size lines for FLOW, not consumption
 Flex lines
 Fuel heating
 Using Fuel Consumption values can lead to undersized lines 

increased restriction on fuel pump
Quick Reference Available in T-030 for Pipe Size
Max Fuel Flow Rate Flex Hose NPS Pipe DN Pipe

GPH (L/hr) No. Size (in.) Size (mm)
Less than 80 (303) 10 1/2 15
81-100 (304-378) 10 1/2 15
101-160 (379-604) 12 3/4 20
161-230 (605-869) 12 3/4 20
231-310 (870-1170) 16 1 25
311-410 (1171-1550) 20 1 1/4 32
41-610 (1550-2309) 24 1 1/2 40
611-920 (2309-3480) 24 1 1/2 40
Only valid for straight runs up to 15 meters.

For complex runs, individual restrictions should be calculated.
Fuel System Notes
 Requires supply and return

lines for both day tank &
engine
 Rupture basin or
dual-wall
 Vent requirements
 Filling provisions
 Fire suppression
requirements
Fuel Tank Type & Location
 Diesel sets up to 1MW include sub-base tanks
 Larger sets may have small Day Tank near genset
 Longer running requirements mean Day / Transfer tanks
would be required
Tank Return Port
Spill return limit, approx 7 ft (2 meters)
Engine Fuel Return

Engine Fuel Pump
 Top of Tank:
– Spill return line should not exceed the maximum
head indicated on engine data sheet
 Bottom of Tank:
– Should not be below finish floor level
– Ideally, always with a positive fuel pressure on
fuel pump
What Size Fuel Tank?
 Decision based on:
Rule of Thumb:
– Genset fuel consumption 1000kVA Genset on 100%
– Application type (required run hours) load consumes 200 Ltr/hr.
Therefore 12 hours =
– Expected duration of outage 2400 litres of diesel.
– Priority and time to re-fuel
– Local regulations requirements
These items tend to push design to a larger tank.
The problem is fuel gets contaminated if not used.
 Recommendations:
– Roll-over fuel 2 times per year
– If this is not possible, plan for fuel maintenance
Fuel Tanks Sizes
 Daily Tanks (from 50 to 1,500 liters)
– Plastic
– Steel
 Bulk Tanks (from 2500 to 60,000 liters)
– Vertical (Cylindrical, Square)
– Horizontal (Cylindrical, Square)
– Underground (Cylindrical, Square)
– Mobile (Iso Containers)
 Fuel Bladders (380 to 760,000 Liters)

Fuel Level Detectors
Float
Magnetic
Switch
Ultra-Sound Level Measure

Pressure Measure
Switch Sensing
4. Exhaust System
Exhaust
4. Exhaust System
Air +
Heat
5. Cooling System
+
+ Sound
Fuel +
Vibration
2
System Restriction
 It is important to keep the exhaust back pressure as

low as possible. Excessive exhaust back pressure can
contribute to poor engine performance and poor
durability by negatively affecting combustion
efficiency and increasing gas temperature.
 To satisfy above, it is important to minimize piping
length, elbow quantities, silencer restriction and to
maximize piping diameter.
Back Pressure Calculation
 The following formula can be used to calculate the
actual back pressure to the exhaust system for a
given length and diameter
 P = L x S x Q²
5184 x D²
L = Pipe Length and Elbows in Ft / Meters
Q = Exhaust flow CFM / m³/sec
D = Inside Diameter of pipe inches / meter
41 lb./cu.ft./kg/m³ , S will vary with absolute temperature of
S = Specific weight of exhaust gas
460 X Exh Temp in F
exhaust gas ( )
P = Back Pressure (p.s.i) must not exceed max. allowable back pressure as shown in
accompanying table
Exhaust Back Pressure
Sample Exhaust Back Pressure Calculation
Exhaust Insulation
Recommended
Exhaust/Silencer Installation
-Silencer supported from building
-Exhaust pipes/silencers
Insulated and away from Intake
-Approved thimble to protect
combustible wall Check...
-Exhaust rain caps and prevailing
wind direction.
-Always slope exhaust away
from engine
-Condensate trap and drain
Valve.
79
A Word About Exhaust Insulation
Exhaust Expansion & Flexible Sections
Exhaust Pipe Termination
5. Cooling System
Exhaust
4. Exhaust System
Air +
Heat
5. Cooling System
+
+ Sound
Vibration
2
Cooling System
 Cooling System should be provided based on Engine Cooling Configuration
– One Pump/One Loop (1P/1L)
– One Pump/Two Loop (1P/2L)
– Two Pump/Two Loop (2P/2L)
– Charge Air Cooling
 On Skid Radiator Cooling : The Radiator fan is Driven by the Engine Shaft
either Directly or with Belt / Pulley arrangement
 Off Skid Radiator Cooling (Remote) : The Radiator Fan is driven by Electric
Motor
– Vertical Type Radiator
– Horizontal (Table Top Type) Radiator
84
Layout – without external pump
 Simple System
 Control
 Auxiliary Supply
 Short Distances
 Back Pressure
85
Layout with external pump
Expansion Tank
 Complexity System
 Control Heat Exchanger
 Auxiliary Supply
 Pumps
 Heat Exchanger
 Expansion Tanks
 Maintenance Pump
86
Dearation
 Expansion Volume
 Vent gases (preventing hot spots)
 Positive Head Pump (prev.
cavitation) Engine
 Fill
 Monitor Level
 Highest Point of the system
Dearation Tank Sizing

Determine the total capacity of cooling
system/loop
Sizing the dearation tanks accordingly to
15% of the capacity of the loop
87
Control
 Auxiliaries Supply
– Voltage/Frequency
– Starting System (direct, soft start, star/delta)
– Pumps
– Electrical Motor Radiator
 Fault Sensing
– Level Sensors (Float Tanks)
– Differential Circuit Breakers (Pumps and Electrical Driven Fans)
– Thermal Protection (Pumps and Electrical Driven Fans)
– Auxiliary contacts Protection devices
 Logic
– Starting Stopping of the System
– Available Inputs/Outputs on the PCC
– Logic for redundant systems
– Variable Speed drive based on the genset loading
88 – Remote Monitoring
Sizing Remote Cooling System
Using just the Coolant Pump of the engine:

Procedure to Verify/check the cross section of piping piping
– Retrieve data from the engine data sheet:
• Coolant Flow
• Maximum Coolant Head Static Pressure ft(m) piping
• Maximum Coolant Friction Head psi (kPa) piping
– Calculate the total length of the vertical pipes in the system
– Calculate the total length of the straight pipes in the system
– Calculate equivalent length of all the fittings and valves
– Calculate the sum of equivalent length of all the fittings and valves with total length
of the straight pipes in the system
– Compare the results obtained to check if they are inside the specified limits
89
Pipe Restriction Calculation For Remote Cooling
Jacket Water Circuit Friction Loss Calculation
INPUT DATA INTO WHITE BOXES
metres of
Pipe internal diameter Friction Loss = 0.62
127 mm H2O
Flow rate 13.7 litres per second 6.07629334 kPa
Pipe length (see below) 77.937 metres The friction loss equals the head (static head) required
to provide the specified flow rate at the end of the specified
Note that for the pipe length, you must include allowances for fittings
pipe system.
Using the "equivalent length" method type in the number of each type
Note that for pipe systems where the pipe diameter
of fitting and the straight pipe length below
in some sections changes, this calculation must be carried
out for each pipe section.
Number of fittings Equivalent length
90 degree elbow 12 4.932
45 degree elbow 0 0 Note that this calculation is designed for water / coolant only.
T straight through 0 0
T through side outlet of same dimension 0 0 Disclaimer
Non-return valve (full bore type) 1 0.0822 Aquatext accepts no responsibility for any losses or
Ball valve (full bore type, fully open) 4 0.4932 damage or other matters arising from the use of this
Gate valve (full bore type fully open) 0 0 spreadsheet. The use of calculations, information and
Length of pipe (metres) 72.43 72.43 advice contained is used solely at the risk of the user.
Sudden contraction in pipe diamter* 2 0.822
*This should be used for a pipe section where the diameter has changed
from one pipe diameter to a smaller one (e.g. a reducing bush)
Pipe Restriction Calculation For Remote Cooling
Coolant flow Restriction Calculation for Genset with Remote mounted Radiator Installation
Project: SAMKO - Qatar
Genset model: C1100D5 Drawing Ref: CME - M - 063 - 001 Rev 0
Rating: 800 Kw Aftercooler Water pump Flow rate: 4.4 L/sec Max External Restriction AC: 35 kPa
Engine model: QST 30 Jacket Water pump Flow rate: 13.7 L/sec Max External Restriction JW: 69 kPa
Remote radiator Core Restriction Aftercooler: 24.6 kPa Remote radiator Core Restriction JW: 7.4 kPa
Total Piping Restriction for After cooler Circuit (from sheet 3): 8.90 kPa
Total External Restriction to the Water Pump (Piping + Rad) Aftercooler Circuit: 33.50 kPa Max Limit per Engine Data Sheet kPa
Total Piping Restriction for Jacket Water Circuit (from sheet 3): 6.0763 kPa
Total External Restriction to the Water Pump (Piping + Rad) Jacket Water Circuit: 13.476 kPa Max Limit per Engine Data Sheet kPa
Note: Static head on the water pump should not exceed 14 meters from the engine crank centre line
6. Noise Control
Exhaust
4. Exhaust System
Air +
2. Ventilation System Heat
5. Cooling System
+
Sound
+ 6. Noise Control
Fuel Installed Genset +
Vibration
2
Typical Sound Levels
140 Threshold of Pain
130 Pneumatic Riveter
120
Uncomfortably Loud 110
100 Jet Fly-over @ 1000’

Lawn Mower Typical Genset Range
Very Loud 90
Heavy Street Traffic
80
70
Moderately Loud Normal Conversation
60
50 Light Traffic
Quiet 40
Library
30
Very Quiet 20 Broadcasting Studio

10 Rustling Leaves
Genset Sources of Noise
 6 main Source of gen-set
noise:
– Engine noise
• 100 -110dB(A)@1m
– Cooling fan noise
• 100-105dB(A)@1m
– Alternator noise
• 80 – 90dB(A)@1m
– Induction noise
• 80 – 90dB(A)@1m
– Structural/mechanical noise
• vibration, Gears etc.
– Un-silenced engine exhaust
• 120-130dB(A)@1m needs to be specifically
taken care of
Source of noise
 Engine mechanical noise
 Exhaust noise
 Cooling fan noise
120dB
 Alternator noise 110dB 95dB
 Induction noise 80dB
 Structural noise
110dB
100dB
Adding Noise Levels
 Sound pressure levels in decibels are based on logarithmic

scale. They cannot be added or subtracted in usual
arithmetical way
Addition of Decibels
Numerical difference Amount to be added to the
between two noise levels higher of the two noise
[dB(A)] levels [dB or dB(A)]
0 3
0.1 - 0.9 2.5
1.0 - 2.4 2
2.5 - 4.0 1.5
4.1 - 6.0 1
6.1 - 10 0.5
10 0
Sound Attenuation Strategies
 Total Noise Level is SUM of all the Sources

– Mechanical Engine Noise
– Fan Noise
– Exhaust
Install 15 Exhaust 94
79 dB(A) dB dB (A)
87.5 dB(A) Std. Muffler
Fan 86 dB(A)
87 dB(A)
Engine 80 dB(A)
Analyzing the Entire System
Often times, specifications will call for a critical grade silencer… but is
it truly decreasing the noise output of the system?
Install
Install 25
15 dB
dB
Residential Exhaust 94
Std. Muffler
79 dB(A) Silencer
69 d B(A)
88
87 dB(A)
87.5
dB(A)
B(A)
Fan 86 dB(A)
87 dB(A) Engine 80 dB(A)
The money and design effort required to accommodate the new

critical grade muffler is essentially wasted; an overall sound pressure
reduction of 0.5 dB(A) could have been greatly increased by treating
the other noise sources (fan and mechanical noise)
Sound Attenuation Strategies
Noise-reduction Strategies
 Acoustic barriers
 Acoustic insulation
 Attenuation of cooling air noise
 Exhaust silencers
 Maximise distance from the source
Acoustic Barriers
 Outdoor applications
– Rigid barriers (steel)
 Indoors applications
– Block walls (sand or concrete)
101
Acoustic Insulation
 Indoor applications and enclosures
 Absorbing materials (Fibreglass)
 High frequencies
 Typical noise reduction from 5 to 20db
Acoustic Insulation - Enclosures
Cooling Air Attenuation
 Attenuators
 Air flow bending
 Remote cooling
Exhaust Silencers. Typical attenuation levels
 Industrial 15dB
 Residential 25dB
 Critical 35dB
 Hospital 45dB
Maximise distance from source
 SPL decreases as distance from the noise source
increases.
 “Rule of Thumb” can be applied to obtain SPL at some
distance from the noise source
SPL0 – SPL1 = 10log (R1/R0)
Example: Genset Enclosure designed for 85dBA @ 1m.

What is SPL at 7m?
SPL0 = 85dBA R0 = 1m
SPL1 = ? dBA R1 = 7m
SPL1 = 85 – 10log(7/1) = 77dBA
Maximise distance from source
77dB – 20dB = 55dB(A)@30m

External Noise Considerations
Sound Attenuation of Cooling Air Entering & Exiting the
Room
Air intake splitter-attenuator limits

Outlet splitter-attenuator break out of engine room noise.
limits break out of radiator
noise.
Summary
 Remember that the room design and sound

attenuation techniques used can have an impact on
equipment performance.
 Protect your equipment and your neighbor’s ears
through the use of enclosures or by locating them
indoors.
 Remember the noise level addition is logarithmic in
nature, so be careful when adding the noise of
different sources.
Acoustic Test Centre
Exhaust
4. Exhaust System
Air +
2. Ventilation System Heat
5. Cooling System
+
+ Sound
6. Noise Control
Fuel Installed Genset +
Vibration
2
Vibration. Mechanical Concept
 Transmission of sound
 Isolation of vibrating components
112
Integral Vibration Isolators
 Rubber AVMs between eng/alt and skid
 Not very effective at low frequencies
113
Pad Vibration Isolators
 Pad Isolators (QSK23)

 Non critical application
 Around 75% average
114
Steel Spring Vibration Isolators
 Critical applications
 Up to 95% efficiency
L Series (QSK60)
115
Vibration Isolating Foundation
 Highly critical applications

 Foundation calculation (T030)
H = Wtset / D x L x W
D(Density of concrete) = 2322 kg/m³
116
Paralleling Basic and Myths
Generator Control Panel
Why Parallel Gensets?
 Reliability
– In situations where load can be split up, failure of one genset leaves the system still able
to serve the most critical loads.
• Better reliability for critical loads
• Poorer reliability for non-critical loads
 Performance
– Small, high speed (1500/1800 RPM) gensets can start faster than larger slow speed
machines
– High speed gensets have better transient performance than slow speed machines
– Stiffer Emergency/Standby “Grid”
 Cost Effectiveness
– May be lower cost to install several small gensets vs. single larger genset
• Especially for systems over 2000kW
• Installation Cost Reductions, Flexibility
– Servicing convenience
– Prime Power: reduced fuel consumption, better load factor
Same Operating Voltage, Frequency, Phase Rotation
G1 G2 G1
G2
LOAD
 With both gensets running and breaker closed, the

voltage and frequency must be identical between any
points on the bus.
Paralleling Functions
REMOTE
EC
ENGINE
 Traditional Designs start with a non-
paralleling genset….
GOV
– EC: Engine Control
• Protection for Engine
AVR GEN
• Start/Stop
• Operator Interface (Alarm/Metering)
– GOV: Governor
• Measure Speed/Control Fuel Rate GCB
– AVR: Automatic Voltage Regulation
• Measure Voltage/Control Excitation
POWER
TO LOAD
Load Sharing for Paralleling
kVAR
kW
kW Demanded by Load
kVA Demanded by Load
 Engines Produce kW--Fuel Rate Controls

 Alternators Make kVA--Excitation Controls
Load Sharing
REMOTE
LOAD
EC
ENGINE
SHARE DATA
GOV
ILS
AVR GEN
GCB
• Add kW Load Sharing Controls: ILS
• Add kVar Load Sharing: Cross Current
POWER
TO LOAD
Synchronizing
REMOTE
EC
ENGINE
LOAD SHARE
DATA
GOV
SYNC ILS
AVR GEN
GCB
POWER
TO LOAD
Genset Protection
REMOTE
LOAD SHARE EC
ENGINE
DATA
GOV
PROT SYNC ILS
AVR GEN
GCB
Minimum Paralleling Genset Protection:

POWER
• Loss of Field (40) TO LOAD
• Reverse Power
Metering/Manual Controls/HMI
REMOTE
TRADITIONAL PARALLEL CONTROL
ALARM
ENGINE
LOAD SHARE
DATA
EC
GOV
METER PROT SYNC ILS
AVR GEN
PARALLEL BREAKER
GCB
CB
POWER
TO LOAD
Load Govern Functions
REMOTE
• Import/Export Control ALARM

• Var/PF Control LOAD SHARE EC
ENGINE
DATA
GOV
I/E VAR/PF METER PROT SYNC ILS
AVR GEN
UTILITY CB GCB
CLOSED SIGNAL
These Functions are all required for Utility

POWER
Paralleling Application TO LOAD
Impacts of Digital Control
REMOTE
ENGINE
POWERCOMMAND
CONTROL
GEN
 Fewer Components
 Less Space GCB
 Better Reliability
 Lower Cost POWER
TO LOAD
ANSI Functions in PCC
GENSET
SURGE SUPPRESSORS
AM SW KW KWH PF 40 32 65 90 51V
VM SW HZ 27 81U 59
86
VM SW HZ 47 SYNC 25
SS
GENSET CONTROL PANEL
SWITCHGEAR TRIP
CLOSE
Standard Genset Controller Panel Fundamentals
What are the common Major control features of a standard
GCP?
 Enhanced Features • Smart Features
1. Digital engine speed 1. AmpSentry protection

governing controls 2. Battery monitoring system
2. Digital voltage regulation
3. Analog and digital AC
metering •Optional features
4. Digital alarm and status
message display 1. Optional Network
5. Generator set monitoring Communications
6. Advanced serviceability 2. Optional Digital Paralleling
7. Certifications
8. Warranty
Standard Power Control Systems
System Controller
PowerWizard 1.1, 1.1+,2.1 & 4.1
EasYgen 2500
EasYgen 3200
DeepSea 7000 series
DCP 10
Deif AGC-4
130
PowerWizard 1.1, 1.1+, 2.1
Features
• Robust electronics package for industry
leading reliability
• Single menu layout for ease of
navigation and monitoring
• Two display languages (Customer &
Technician Language) • 5 spare fault channels
• Shortcut keys for instant access to • Configurable sender input
engine or AC metering • True RMS Voltage Sensing
• Run/Auto/Stop keys with LED indicators • Engine and AC Monitoring
• Dedicated fault reset key & main menu • CAN 1 Data Link for communication to
key electronic engines, CAN 2 Accessory
• Serviced using standard EST Data Link for additional modules (PW2.1)
• 40 unique events log configuration • Integrated metering and controls aiding
reliability and ease of service (PW2.1)
• 10.5-32V DC providing a single module
to cover the whole FG Wilson generator • Generator set voltage and over/under
set range frequency protection (PW1.1+)
• Comprehensive range of standard • MODBUS connection to building
features and options to ensure the most management system via RS485 (PW2.1)
appropriate configuration for your needs • Power metering

EasYgen 2500
Features
• Capable of set-to-set synchronising for

up to 16 generator sets
• User friendly interface • Engine start / stop and generator set
• Easy system navigation via measuring and protection
programmable soft keys • Running hours balancing
• Multiple communication protocols for • Breaker control: synchronization, open-
communication with Engine Control close control, only- open control,
Units (ECUs), external I/O boards, PLCs breaker monitoring
and modems • Dead bus closure negotiation
• Multilingual capability: English, Chinese, • PLC-like programming with Logics
French, German, Italian, Japanese, Manager
Polish, Portuguese, Russian, Spanish • 300-entry, time and date stamp log
and Turkish
• Operating hours / start / maintenance
• Capable of working with all common counters
industrial interfaces
• Configurable trip levels / delays / alarm
• Power and reactive power load classes
sharing up to 16 units including load-
• Field configurable application settings
dependent start / stop
• Multi-level password protection

EasYgen 2500 Control System Architecture
Protection
Service / Configuration
Generator Set
USB
SCADA
• Over / under voltage
• Over / under
USB to DPC frequency
CAN Cable
• Dead bus detection
Service Port RJ45 • Overload
Loadshare Line • Reverse / reduced
57/58 power
CAN 1 10 Digital Inputs
11 Digital Outputs
• Time over current
CAN Bus
Engine Level 87/90 5 Analogue Inputs • Instantaneous over
CAN 2 current
2 Analogue Outputs
• Inverse time over

MPU
Frequenc
current
Voltag
Biasing
y
g
Biasin
e
55/56
Measuring
• Phase rotation
• Unbalanced load
ECU
• J • Power factor
1939
Engine
• Over / under speed
• 16 Digital Inputs
2 xI / O
Expansion • 16 Digital Outputs
• Battery over / under
board voltage
• Speed / frequency
mismatch

EasYgen 3000 series
Features
• Capable of generator set-to-set, set-to-mains
and multiple set-to-mains synchronisation for
up to 32 generator sets
• Enhanced system flexibility meets demanding
customer specifications
• User friendly interface via 320x240 pixel
graphical interactive 5.7”LCD • Configuration via PC/laptop with ToolKit service
tool
• Easy system navigation via programmable soft
keys • Engine start / stop and generator set
measuring and protection
• Multilingual capability: English, Chinese,
French, German, Italian, Japanese, Polish, • Automatic base loading
Portuguese, Russian, Spanish, Turkish and • Running hours balancing
Finnish • Import / export control
• Multiple communication protocols for • Dead bus closure negotiation
communication with Engine Control Units • 300-entry, time and date stamp log
(ECUs), external I/O boards, PLCsand modems
• Operating hours / start / maintenance counters
• ECU monitoring and alarm management as well
• Configurable trip levels / delays / alarm classes
as remote start / stop and control commands
• True RMS voltage and current sensing • Field configurable application settings
• CAN network communication/control to engine • Multi-level password protection
ECU • RP3000 remote display panel available for
• SerialModbusRTUcommunicationfor SCADA management and control from adjacent plant
annunciation and external control room

EasYgen 3000 series Control System Architecture
Protection Generator Set
Service / Configuration
• Over / under voltage and
ACMeasurement: frequency
• 4 x U Gen, 3 x l Gen
• 2 x U Bus • Dead bus detection
• 4 x U Mains, 1 x l Mains
Guidance / Load
Share Level
RS232 • Overload
CAN 1 • Unbalanced load
10 Digital Inputs
12 Digital Outputs
• Reverse / reduced power
PLC/
SCADA
RS4851
3 Analogue Inputs • Time over current
• Instantaneous over current
2
CAN
Frequenc
U
MP
Voltag
g
Biasin
e
Biasing
y
• Measured ground fault
CAN Bus Engine Level
• Phase rotation
• Power factor
• J 1939 including
ECU
100 SPNtext events
Engine
• Over / under speed
2 x I/O • 16 Digital Inputs
Expansion • 16 Digital Outputs • Battery over / under
board
voltage
• Auxiliary excitation
• Speed / frequency
MCB GCB mismatch
Mains
• Over / under voltage and
frequency
• Phase shift
• Rotation field

DeepSea 7000 series
Features • CAN and magnetic pick-up sensing

• Configurable inputs/outputs (11/8)
• Fuel usage monitor and low level alarms
• Remote communications (RS232,RS485,
Ethernet, Modbus, RTU/TCP)
• Configurable event log (250)
• Integral PLCeditor
• Power monitoring (kW h, kVAr, kv Ah, kV Ar
h), reverse power protection, kW overload
protection
• Load switching, load shedding & dummy load
outputs
• Data logging (HDD/USB)
• DSE Configuration Suite PC Software
• Tier 4 CAN engine support

DCP range
Features
- Automatic start control module
- Monitoring, protection, operational status,
fault conditions and metering displayed
via LCD & LEDs
- Run / Auto keys with LED indicators
- Symbols for simple, intuitive control
- Robust electronics package
- Configuration of parameters via panel or
laptop installed free software
- True RMS Voltage Sensing
- Engine & AC monitoring
- Under / Over voltage protection
- Large graphic LCD screen
- RS232 USB port for set point programming
137
Deif AGC
Features
Suitable for a wide range of applications, the Deif AGC-4’s standard sequences include backup power, start/
stop, synchronisation and load sharing. The Deif AGC-4 supports serial communication protocols including
Modbus(RS485,USBand TCP/IP) and Profibus.
• TheAutomatic Genset Controller,AGC,contains • Load-dependent start and stop

all necessary functions for protection and control • Load management
of your generator set • Emulation for Fast Training & I/O test
• Multiple operating modes including backup • Hot Standby – Change to backup generator set
power, start/ stop, synchronisation, and load controller on the fly
sharing
• Fully compatible with AGC3
• Synchronisation of up to 56 breakers
• Multi-master power management

What is MLD
Description: Gensets share information to understand system load and

available system capacity. Gensets start and stop themselves based on system
load (kW).
If Capacity of running gensets > Load level (set point) Start

Genset
Gensets are turned off
Load
If Capacity of running gensets < Load level (set point)
level
Additional gensets are started Stop
Genset
 The priority of which gensets turn on and off is determined by the operator, or
by the
number of hours on the genset
 System is Masterless as logic is built-in. No extra hardware such as a Master
control is required
139 30/03/2017
Master Control Systems & Remote Monitoring
Master Control Systems - Overview
Manual Control – The lowest cost method. On larger systems

this basic sync and load share becomes totally unmanageable.
Master Control – Different types of Digital Master Control

systems available for monitoring and/or control of a power
plant.
Two Main Type of Parallel Operation
• Isolated Bus Paralleling: Is were two or more generator
sets are Paralleled with each other onto a common bus,
but this common bus cannot be Paralleled with Utility –
Generator sets Never Operate in Parallel with the Utility
• Utility Bus Paralleling: Is were two or more generator

sets are Paralleled with each other onto a common bus
and this bus can be Paralleled with Utility – Generator sets
May Operate in Parallel with the Utility
Typical Master Controller System Functions
– System AC metering
• Ammeter, voltmeter, frequency, kW, etc.
– System Status display
• Availability of sources
• Status of load service
– Operator Interface for Total System
• Means by which to change system parameters
– Manual Control provision
• Test functions
– and, Load Control…
– Load Add & Shed control & prioritization

• Staged transfer commands for emergency loads
• Control signals to the load shed contactors
– Load Demand management
• Continuous monitoring of the total kW demand
• Management of generating capacity to suit site kW demand
• Optimise system operation
• Optimum fuel efficiency
• Lower running costs
– Lead unit management

• User definable lead unit assignment
• Rotation of lead unit based on run hours
• By-pass management of lead unit should it fail
– Extended Parallel Peak Shave & Base Load
• kW load management to reduce or produce kW
• DMC enables multiple paralleled sets operation in either
Peak Shave or Base load mode.
Typical Master Controller System
The Complete Package

“The Power Of One”
Typical Master Communication principle
146
Most common system – SCADA (view 1)
147
Most common system – SCADA (view 2)
148
LV & HV Switchgear
–Partnerships with ‘strategic’ manufactures enables us to

offer competitive switchgear panels.
–Adaptation and integration of the controls is undertaken by
our staff.
HV product up to 33KV
Protection devices
(G59) & studies
Fixed & Withdrawable
Breakers
Meets International
Standards
150
Network Layout
Modbus
BMS or PC
GCP
ModLon
PCCNet
Lonworks
AUX101 Annunciator
PCC3201 PCC3201 PCC3201

AUX102
151
Q&A
THANK YOU
Comparison Between MV Generator & LV Alternator + Transformer
Configuration
MV Alternator Genset LV Alternator Genset +

Parameter
Package Transformer Package
Requires same space as LV alternator

Space Requires 30% more space due to transformer
only
Approx. 10% heavier than a LV genset - Separate foundation needed for transformer
Foundation
due to the alternator with oil disposal pit if applicable
Single run of 3c cable connected

Cable connection Multiple runs of LV cables, or bus duct
directly to MV circuit breaker
Varies from 95 to 95.5% for alternator

additional 1.5% losses for transformer( Lower
Alternator efficiency Varies from 96 to 96.5 %
efficiency leads to higher fuel consumption for
prime power application >2000 hr/year
Voltage dip function of alternator reactance +

Function of X’d (transient reactance) of
transformer reactance. Application of 100%
Transient performance alternator. Voltage dip when applying
kVAr load will result in dip of 25% or more
(voltage) 100% kVAr load will result in dip of
depending on transformer impedance
approx 20%
(assumed to be 5% for above dip)
154 30/03/2017
Comparison Between MV Generator & LV Alternator + Transformer
Configuration
MV Alternator Genset LV alternator Genset +

Parameter
Package Transformer Package
Simple system employing either direct
System earthing for MV Complex system due to interposing step-up
grounding of alternator neutral or
system transformer
NEB(Neutral Earthing Board)
Complex protection system to discriminate

System protection Standard protection system
between alternator and transformer faults
Single point of coupling on the electrical

Synchronizing system Multiple point of coupling (LV and/or MV)
bus
Generator step up
100% voltage dip possible during start up with
transformer inrush current Not applicable
one Genset energizing multiple transformers
during electrical blackout
Complex scheme with interlocks between MV

Simple scheme for Circuit breaker
MV switchgear switchgear and LV switchgear to prevent
operation
inadvertent closing
30/03/2017 155

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Technical Seminar 2017 - Lagos

Power Generation Design Awareness

By JMG Power Generation

2) Gen-set De-rate Verification / Calculation

3) Gen-set Sizing Consideration

4) Generator Installation Design Consideration

a) Installation Layout Consideration

5) Paralleling Basic and Myths , Generator Set Controls

6) Master Control System & Remote Monitoring

3 JMG Ltd Confidential

ISO 8528 Part 1 defines these ratings

4 JMG Ltd Confidential

Question – What causes the Derate on a Genset?

5 JMG Ltd Confidential

What effects your choice of Genset rating?

6 JMG Ltd Confidential

7 JMG Ltd Confidential

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11 JMG Ltd Confidential

Standby Rating 1650kVA

Prime Power Rating 1500kVA

Limited time Prime Power 1500kVA

Continuous Operating Power 1250

12 JMG Ltd Confidential

13 JMG Ltd Confidential

What is the genset derate?

14 JMG Ltd Confidential

15 JMG Ltd Confidential

The Derate Calculation is divided into two parts

16 JMG Ltd Confidential

• Genset Model or Required Power

Example: P400_350kVA_50C_1000M ASL_400V/50Hz

17 JMG Ltd Confidential

Alternator Derate Power =

18 JMG Ltd Confidential

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– Fan power = 14kWm

– From Engine Derate Formula =

23 JMG Ltd Confidential

24 JMG Ltd Confidential

– Alternator Efficiency @ Prime Power = 93.4%

– From Engine Derate Formula =

– Prime Engine Power =

• {[324.2 x (1-6%)]- 14kWm} x 93.4 = 271.5kWe

25 JMG Ltd Confidential

26 Alternator Prime Rating

27 JMG Ltd Confidential

29 JMG Ltd Confidential

 Alternator ESP power = 3200 x 0.94 x 1 = 300.8 KWe

30 JMG Ltd Confidential

– Prime Engine Power =

– Alternator Prime Rating Power = 320 x 94% x100% =

– Therefore the output of the genset is limited by the Engine

31 JMG Ltd Confidential

 Canopies, Containers - Usually higher derate due to the increased

 Power Factor considerations - Consult the alternator operating chart –

 Air filters - Potential additional alternator de-rate 5-10%