One powerful future.

DC Forum - Coppet, le 17 septembre 2014
Avesco - Energy Systems
Gian Franco Broggi
Loris Buess
Avesco – Une entreprise familiale
3’400 employés
Chiffre d’affaire 2013 :
910 MioCHF
Fondé en 1869
6e génération
Equipements Centrales à béton
de compactage et d’asphalte
Equipements de
chantier
Production
d’énergie
Sièges d’Avesco et Ammann à Langenthal/BE
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Plus de 1’000 collaborateurs sur le site
Plus de 120 apprentis
Plus de 100 collaborateurs pour Avesco
Energy Systems
Avesco Energy Systems - Succursale Suisse Romande
•
•
•
•
•
•
Avesco à Puidoux : plus de 50 collaborateurs
Siège de la société Avesco Rent SA
Avesco Energy Systems : depuis le 1er juillet 2014 à Puidoux
Une équipe motivée et proche de vous
Conseil de vente, réalisation de projet, service
Hotline 24/7 en français
Des installations de secours clés en main
Engineering
Systèmes de contrôle
Installation complète
Transport et montage
Tests en usine
Power Systems : en croissance
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La société opère principalement dans 3
segments de produits
- Resource Industries
- Construction Industries
- Power Systems
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Selon Caterpillar : “Global economic
growth will drive increasing demand for
energy and transportation during the
coming decades”
Cat dans le monde :125 000 employés
Il y a plus de 450’000 génératrices Cat
installées dans le monde.
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Europe, Africa & Middle East
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La région EAME constitue une importante unité de production ainsi
que la plus grande division de distribution Caterpillar en dehors des
États-Unis.
Le siège de Caterpillar EAME-CIS se trouve à Genève
Les distributeurs Cat® de la région EAME emploient plus de 26’000
personnes.
Avesco est le distributeur exclusif de Caterpillar en Suisse depuis
1931.
Groupes électrogènes
Comment assurer un dimensionnement optimal en
fonction des critères de l’Uptime Institute
Loris Buess, Caterpillar
17 Septembre 2014
One powerful future.
“The generator set shall be rated 2MW
continuous”
TRANSFORMED BY 6 SIGMA
Page 2 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Ratings
Data Center Genset Usage
Complying with Uptime Requirements
TRANSFORMED BY 6 SIGMA
Page 3 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
What are ratings?
• Approved methods of applying gensets
• Gensets with different ratings are not necessarily
different gensets
• Ratings are trade-offs between:
– Run-hours
– Average load (Load Factor)
– Max power available
TRANSFORMED BY 6 SIGMA
Page 4 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
ISO8528-1
• ISO = International Standards Organization
• Developed to provide consistency across
manufacturers and industries
• Defines 4 ratings:
–
–
–
–
Continuous Power (COP)
Prime Power (PRP)
Limited-Time Running Power (LTP)
Emergency Standby Power (ESP)
• Manufacturers usually use different specifications
TRANSFORMED BY 6 SIGMA
Page 5 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
ISO vs Caterpillar
ISO 8528-1 Ratings
Caterpillar Ratings
• Emergency Standby
• Emergency Standby
• No ISO equivalent
• Standby
• No ISO equivalent
• Mission Critical Standby
• Limited-Time Running
• Load Management
• Prime Power
• Prime
• Continuous Power
• Continuous
TRANSFORMED BY 6 SIGMA
Page 6 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Rating Trade-offs
2500
+10%
Overload
2250
500 Hrs
Avg Load
500 Hrs
1500
Nameplate
500 Hrs
1750
Unlimited Hrs
2000
Unlimited Hrs
Overload
MC
4
Standby
Standby
5
1250
Continuous
1
Prime
2
Load
3
Mgmt
Avg Load vs Load Variation
Avg Load vs Peak Demand
& Peak Demand
TRANSFORMED BY 6 SIGMA
Run Hours vs Avg Load
Page 7 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Ratings: Common Approaches
• Designing for worst-case scenarios is the norm
– Max possible load
– Worst possible ambient conditions
• Doesn’t reflect real world operation
• Under-loading concerns
• Doesn’t provide optimal value
TRANSFORMED BY 6 SIGMA
Page 8 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Real World Usage
2500
Includes
Commissioning
Tests
1 hr
in 12
1000
1
Continuous
2
Prime
Load
3
Mgmt
• 78 Units (2006-2010 delivery)
• Avg hours per year = 130
• Max hours per year = 238 hrs
TRANSFORMED BY 6 SIGMA
MC
4
Standby
500 Hrs
500 Hrs
1250
500 Hrs
1500
Unlimited Hrs
1750
Unlimited Hrs
2000
5
Standby
130 Hr AVG
(25 Max)
2250
AVG LF
Data Center
6
Histograms
• Avg Load Factor = 49%
• Avg time @ nameplate = <0.5%
• Avg time >85% = ~14.25%
Page 9 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Real World Usage
MC Standby
Under-loading Concerns?
TRANSFORMED BY 6 SIGMA
Page 10 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Uptime Requirements
• Tier Standards:
“Engine generators for Tier III and IV sites shall not have a limitation
on consecutive hours of operation when loaded to ‘N’ demand.”
(Topology paper section 2.5.2)
• Key Uptime requirements
– No limitations on consecutive run hours
– No limitations on load factor
TRANSFORMED BY 6 SIGMA
Page 11 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Uptime Compliance
• No limitations on consecutive run hours
Caterpillar’s Mission Critical Rating:
“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.”
• Maintenance consequences…
TRANSFORMED BY 6 SIGMA
Page 12 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Uptime Compliance
• No limitations on load factor
– Generator set will not see 100% load factor over
extended periods of time.
• Load is vary rarely close to 100% (see Real World data)
• UPS recharge: 10 to 20% of UPS load
• Chillers/CRACs will cycle based on time of day / season
• Caterpillar’s standby and mission critical standby
ratings comply with Tier III and IV requirements
TRANSFORMED BY 6 SIGMA
Page 13 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Compliance process
• Project-specific
• Reviewed, validated and signed by an Caterpillar
person recognized by the Uptime
• Highlights compliance with Uptime Tier III and IV
standards
• Allows to optimize the sizing of your Generator Set
TRANSFORMED BY 6 SIGMA
Page 14 | CATERPILLAR CONFIDENTIAL: YELLOW
One powerful future.
Conclusion
Work with experts to size your system
See you at the
TRANSFORMED BY 6 SIGMA
stand!
Page 15 | CATERPILLAR CONFIDENTIAL: YELLOW