Clayton Taylor
CEO
ComRent
®
International, LLC.
24
Hour Tests Are Needed!
24 Hour Tests Are Needed!
• New
New way of testing
way of testing
• Ways to sell through testing
• Go after installed base
• Uptime and compliance
2
Eventually Generators Will Be Put To The Test
y
• Ice storms
I
t
• Black outs
• Earth quakes
• Hurricanes
Hurricanes • Know what you don’tt know
you don
know
3
4 HR Method At 1.0 – Not Adequate
4 HR Method At 1.0 Not Adequate
• 4 hr does not replicate realistic emergency situations
• Consider multiple day tests up to 5 days
• Does not provide for adequate transient testing
• 1.0 power factor does not match real‐world loads at the facility
at the facility
• .9 leading power factor with capacitor becoming more important
more important
• Not enough run time to validate the system through temperature, testing and installation g
p
,
g
warranty
4
Old Way – 4 Hour Method
Old Way 4 Hour Method
• Low voltage load banks (typically 480 VAC) • Must be used with step down transformers • Systems can come Systems can come “pre‐wired”
pre‐wired with all with all
equipment mounted to a single trailer; or can come in separate containers that need to be field
come in separate containers that need to be field connected
• Low voltage load banks and transformer L
lt
l db k
dt
f
assemblies introduce more components that can f il d i t ti
fail during testing 5
24 Hour Medium Voltage Load Banks
• Resistive or reactive load bank • Contains resistors or reactors that operate Contains resistors or reactors that operate
above 690 VAC and below 15,000 VAC • Permanent/portable medium voltage load Permanent/portable medium voltage load
banks often used for commissioning power plants maritime electrical systems standby
plants, maritime electrical systems, standby generator systems and substations • The most common voltages used are 5kV Th
t
lt
d
5kV
(4,160V) and 15kV (13,800V)
• Commissioning power systems
6
Low Voltage Load Banks vs. Medium Voltage Load Banks d
k
•
•
•
•
•
Pieces
C
Connection points
i
i
Points of failure
Mutual inductance
Labor
•
•
•
•
•
Pieces
C
Connection points
i
i
Points of failure
Mutual inductance
Labor
7
8
9
10
Industry Case Studies
24 HOUR TESTING, CASE IN POINT…
24 HOUR TESTING, CASE IN POINT…
11
Water and Wastewater Emergency Power
Why Testing Was Needed:
• Commission
Commission proper operation of proper operation of
the entire system ‐ from fuel line through transfer switch
• Generators should be step‐
loaded to accurately reflect system demands and ensure proper emergency load sequencing
• Transient response, noise, p
,
,
vibration and fuel‐use rates can be reviewed during the test
Prevent disruption of a critical
• Prevent disruption of a critical pumping process
12
Water and Wastewater Emergency Power
Water and Wastewater Emergency Power
Project Scope:
j
p
– 2.8 MW resistive load at 4160V to generator
– Commission new Commission new
equipment at pump station
• 3MW of resistive load banks, 3MW f i ti l d b k
a 7MVA transformer, and switchgear with medium and low voltage cable
low voltage cable
• Labor for unit cable runs and tie in for the transformer
13
Data Centers
Data Centers
• Medium voltage load banks eliminates the use of ttransformers for testing f
f t ti
multiple generators in a data center pod
data center pod
• Safer for the generator since it is not subjected to
it is not subjected to fluctuations in voltage and current when a transformer is used to step the voltage down for low voltage load b k
banks
14
Oil and Gas
Oil and Gas
• Ensure that gas turbine generators continued to work while switching out analog controls for digital controls
• Generators were absolutely y
critical to the ongoing operation of the field. If the turbines ever failed – future flow rates would have been lost in the oil field
• With medium voltage load With medium voltage load
banks, the performance of the new digital controls was validated and the continued operation of the field ensured 15
Cruise Ships
• Losing generator power at sea is a catastrophe that makes front page news
• Medium voltage load bank testing right to the dock before
testing right to the dock before the ship sets sail
• When a cruise line installs new diesel generators , load bank testing ensures ships keep the lights on and the propellers
lights on and the propellers turning
• Never have to say DIW
• Happiness aboard ship
16
Always Specify A 24 Hour Test
Always Specify A 24 Hour Test
• Closing
Closing statements
statements
– Leaving future risk and downtime intact
– 5‐day test to mimic 100 day storm event
– Generators don
Generators don’tt run run
under water (flood plain operation)
• Recap • Enforce key messages
17