P2 Power Solutions

Diesel Generator Primer

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Diesel Generator Working Principle

chemical

DIESEL ENGINE

mechanical

ALTERNATOR

electrical

LOAD

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Diesel Generator Fuel Consumption Pattern

per Unit Fuel Consumption vs % Loading
250

200

litre/month/kVA

efficiency increases with DG size

150

100

50

maximum efficiency @ >70% loading

0 50 kVA 75 kVA 250 kVA 375 kVA

25% 88 66 51 50 49 48

50% 126 106 84 82 81 80

75% 175 139 120 117 116 115

100% 219 175 158 157 156 156

500 kVA
750 kVA

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Diesel Generator Operating Guidelines

Ensure steady load conditions Minimize load fluctuations Ensure balanced loading Minimize load harmonic distortions Ensure optimum loading (>70%) Ensure air at generator intake is cold and dust free Ensure fuel oil storage, handling and preparation as per manufacturers' guidelines Calibrate fuel injection pumps frequently

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Diesel Generator Load Characteristics

Increased current demand Increased winding losses Underutilization of capacity: increased capital expenditure, lower efficiency.

Unbalanced output voltages Heating in alternator windings Underutilization of capacity

Overstressing of generators Distorted voltage profile Heating in alternator windings Underutilization of capacity

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Case Study I
Power Factor Improvement on DG DG Specifications: 3 phase, 415V, 50Hz, 500kVA. Operation: 6000 hours/yr
Contents Operating Condt.-1 Operating Condt.-2

Power Factor
Rated Current in Amps Avg. Load in kW kVA Current in Amps Fuel Consumption Full Load Copper Loss in kW Copper Loss in kW Saving in Copper Losses For 6000 hour Operation Potential Saving in Fuel

0.65
695.60 250.00 384.6 535 3kWh/Lit. 12 12*(535^2)/(695.6^2)=7.1 7.1-3.5 kW = 3.6 kW 3.6 x 6000 kWh = 21,600 kWh 21600/3 lit./yr= 7,200 lit./yr

0.93
695.60 250.00 268.8 374 3kWh/Lit. 12 12*(374^2)/(695.6^2)=3.5

Potential Savings in Rs.@Rs. 40/lit. = Rs. 2,88,000 per year

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Case Study II
Parallel Operation of DG sets
Contents Operating Condition-1 Operating Condition-2

Loading Factor
DG in Operation(Parallel) Dg Operationin Hrs Total Energy Generated(kWh/yr) Fuel Consumption Power Factor Total Fuel Consumption Cost Saving in Fuel Consumption Annual Saving in Rs.

60%
1*1000kVA & 2*500kVA 5000 4,80,000 3kWh/Litre 0.7 1,60,000 Lit. 6400000

80%
1*1000kVA & 1*500kVA 5000 4,80,000 3.6kWh/Litre 0.7 13,3333.33 Lit. 5333333.2

1,60,000 -13,3333.33 =26666.7 litres

6400000 - 5333333.2=1066668

Total savings per year (5000 hrs. operation) = Rs. 10,66,666.8 Lakhs

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PF Correction Benefits
Efficient loading Optimum capacity utilization

Reduced heating

KW loading should be within limits at all times

Reduction in Peak current demand

Reduced losses
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PF Correction Capability Curve

Red: Critical Zone

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PF Correction Traditional Solutions

Large footprint
Risk of over compensation

Potentially damage D.G

Stepped correction

Voltage transients

Slow response
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Active Power Conditioner Technology

Iactive

Ireactive

Iharmonic

ILoad

Ireactive

Iharmonic

IAPC

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Active Power Conditioner Technology

ID.G

IAPC

ILoad

D.G

active

Load
reactive + harmonic

APC

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Active Power Conditioner Technology

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COMPARISON SHEET Active Power Conditioner

P2 Power Active Filter Speed Technology Effectiveness Power Factor (PF) Correction Leading/Lagging PF Load Balancing Harmonic Compensation Neutral Correction < 0.2 milli seconds Stepless current compensation Effective with highly fluctuating loads True PF compensation Both Leading/Lagging PF compensation Negative sequence current injection Harmonic compensation Possible with 4 wire system FOOTPRINT

Hybrid PF Compensator
P2 Power Hybrid Compensator PERFORMANCE < 0.2 milli seconds Stepless current compensation Effective with highly fluctuating loads Displacement PF compensation Both Leading/Lagging PF compensation Negative sequence current injection No Harmonic Compensation Not possible

Substitute Technology
APFC, RTPFC Response time in seconds Stepped kVAR compensation Ineffective with fluctuating loads Displacement PF compensation Lagging PF compensation only No load balancing No Harmonic Compensation Not Possible

Size Advantages
Installation (per Ampere) Resource Intensive Capital Cost Operating Cost Returns on Investment

Smallest Footprint
COST `3400~`4200 Smallest space requirement Reduced failures Low operating cost High Improved PF Better voltage profile Reduced failures

Small
`2300~`2800 Low on space requirements Reduced failures Low operating cost High Improved PF Better voltage profile Reduced failures MAINTENANCE Modular design Virtually maintenance free

Largest Footprint
`1000~`1800 Increases cost of space Can increase failures due to resonance Recurring cost of capacitor replacement High with non fluctuating loads Ineffective with fluctuating loads Introduces voltage transients Can increase failure due to resonance Easy Maintenance Recurring cost of capacitors/contactors

Maintenance requirements Spare parts requirements

Modular design Virtually maintenance free

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Thanks!

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