Genset Controllers for Complex
Hybrid System Set-ups
16. September 2013
Jakarta Indonesia
Clemens Grosskinsky
Sales Director PG&D
Woodward GmbH Stuttgart/Germany
Engine Systems
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Woodward Business Units
Energy
Aerospace
ES
• Genset Controllers/
Power Management
• Protection and
Control Relays
• Solutions for
Diesel-, Gas- and
Hybrid Power
Stations,,
Engineering
Services, SCADA
ITS
• Fuel Delivery
Systems
• Ignition Systems
• Electronic Engine
Control & Electrical
Sensor Suite
• Lube & Scavenge
Systems
• Combustion
Systems
•
•
•
•
•
Fuel Pumps, Mixers
Fuel Injectors
Actuators/Solenoids
Governors
Digital turbine and
compressor controls
• Overspeed
protection
• Wind Converters
ATS
•
•
•
•
Fuel Pumps
Fuel Mixers
Fuel Injectors
Drive-by-wire
throttles
• Actuators/Solenoids
• Governors
• Digital controls
AS
•
•
•
•
•
•
•
Motors
Sensors
Gearing
Electronics
Actuators
Integrated Systems
Flight Deck Control
Control Capability
Woodward Power Management Controls
easYgen-3200
easYgen-3500
LS5
easYgen-2000
easYgen-1000
easYgen-300
Paralleling
Non-Paralleling
System Complexity
DSLC-2
MSLC-2
Genset Controller easYgen-3000 line
Paralleling up to 32 gensets
Inbuilt PLC logic
Direct interfacing to
AVR’s & SG’s
ECU communication
14 languages
AMF & ATS
Interconnection
Synchronization
Load dependent Start & Stop
Load & VAR sharing
Mains protection
CAN OPEN & Modbus
Communication
easYgen-3200
Soft Loading features
Neutral Interlocking
Peak Shaving
Clear colored HMI
Remote Control
Generator protection
Load Shedding
External
I/Os
Engine protection
Date& Time, Alarm history
30kVA small gas LPG Package DENYO Japan
GCB
easYgen-3500
Rental
G
CANbus
J1939
Woodward
ECM + L-Series ITB
Termomanaus 156 MW Diesel Power Station
220kV
34,5kV
In total 288 (9 groups
of 32 Diesel Gensets
are operated parallel
to the Brazilian grid
..................
440V/60Hz
GCB
GCB
easYgen-3200
G
P675P5
540kW
Group 1
32 sets
GCB
easYgen-3200
GCB
easYgen-3200
G
G
P675P5
540kW
P675P5
540kW
Group 9
32 sets
easYgen-3200
G
P675P5
540kW
MV Steam Turbine Application - Godavari Sugar
MCB
MCB
Bus 1
Bus 2
TB
MCB
MCB
MCB
Plant Load
max 7MW
TB
TB
GCB
GCB
GCB
G
G
G
TG 1
10MW
TG 2
15MW
TG 3
20MW
8
Single Genset versus Multiple Gensets
Advantages Single Genset:
- Cheap Solution, lower CAPEX
- no need for paralleling equipment
Disadvantages:
Advantages Multiple Genset:
- redundancy through n+1 genets
- lower OPEX through fuel saving
- Smart power management
(LDSS load dependent start&stop)
- no down time during service
- application is always operated
in the best efficient way
- no significant voltage, frequency and
load dips when load is changing
- modular, scale able system
- no redundancy
- down time during service
- Power output single Diesel
depending on required load
- Genset oversized: operated inefficient
and carbonization of the pistons
- Genset undersized: heat damages
Disadvantages:
- frequency, voltage dips
- Higher investment , CAPEX
- higher OPEX through higher fuel consumption
- logistical topic of dimensions
9
Case Study Hatz Diesel – Office Building in Africa
How much Diesel Genset Power (kW) is required to power this building in
Free Town/ Sierra Leone?
10
Before Upgrade – Single Set Installation
- Single Diesel genset 108kW/135kVA Turbo prime power,
- Original plan was to use it as standby system
- Unstable bad public grid resulting in continues operation of the single genset
- Significant frequency, voltage dips and peaks at load changes
- Operated inefficient and engine damage by combustion deposits
- Low load operation not permitted by manufacturer (warranty, lifetime, etc)
- Single Genset replaced after only 5000 hours
11
After Upgrade to 4x25kW100kVA DG’s
100 kW continuous at 1500 rpm  75 dB(A)
400 kVA instantaneous, short duration
12
After Upgrade – Multiple Set Installation
- Application operated without interconnection in a micro grid island mode
- 4 x 25kW/100kVA air cooled Hatz Twin packs
- Power quality, no noteworthy dips
- Enormous Fuel saving,
- Amortization of genset upgrade within 2-3 years depending on operating hours
- Hoppecke battery bank 48 VDC OPZS 4000Ah battery as IT backup
- During day 5kVA PV power direct connected to the bus (negative load)
13
Fuel Consumption Single Set - Multiple Sets
Fuel consumption
g/kWh
Single Diesel Genset
108kWTurbo
Up to 80% of operation time,
a single genset is under utilized
and consuming more fuel
4 x 25 kW
Diesel Gensets
Load
14
Fuel Consumption Calculation
2 Hatz Twin Packs (4 gensets 4 x 25kW/400kVA)
Spec. Fuel Consumption: 245 g/kWh
Average Annual 400,000 kWh/year (5000 h)
@ 0,85 kg/l diesel fuel = 115,294 l/year
Single Automotive Engine Genset 108kW/135 kVA
Spec. Fuel Consumption: 300 g/kWh
Average Annual 400,000 kWh/year (5000 h)
@ 0,85 kg/l diesel fuel = 141,176 l/year
Difference:
25,882 l @ 1,3 USD = 33,646 USD savings /year
with a modular n+1 genset solution
PV as negative Load (Real Case)
• Volatile Power (PSolar) < 20% (1)
• 20% < Volatile Power (PSolar) < 60% (1)
20
12
-8
• Transients can be balanced with
standard mechanism
• Transients (due Load, Shading)
cumulate and can cause instability
• Reverse Power - Black-out
PGenerator = PLoad – Psolar
PGenerator = 12 – 20 = -8
(1) = max achievable contribution of renewables as average value, momentary values may exceed that range
SMA - Woodward
PV - Diesel Genset - Solution
PV-Power
Station
Diesel Power
Station
SMA Fuel Save
Controller
Modbus TCPiP
Modbus TCPiP
ESENET
Gateway
SMA Interface Module
(Cluster Controller)
...
...
...
CAN Open
modular extendable
modular extendable
...
Power Distribution / Protection
...
1
Sunny TriPower
...
2
Sunny TriPower
...
3
Sunny TriPower
...
...
n
Sunny TriPower
1
Genset
2
Genset
...
n
Genset
Woodward Channels in South East Asia
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