industrial power systems inc rtg & vsg … f06 bill young... · youtility inc. industrial power...
TRANSCRIPT
RTG & VSG Presentation
EGSA ConferenceSept. 18, 2006
Alan McDonnell Bill YoungSales Manager PresidentYoutility Inc. Industrial Power Systems Inc.11 Executive Dr. Hudson, NH 03051 3010 Powers Ave. Jacksonville, FL 32259
INDUSTRIAL POWER SYSTEMS, INC
VSG – Fixed Speed Comparison
• The following slide shows a comparison between the fixed speed power generation model and a variable speed industrial model CAT C32 ACERT, one of their newest electronic engines
• Both engines meet EPA Tier 2 emissions
Total Fuel (lb-hr)
Power (kWe)
1000600200 400 800
500
300
200
100
400
100
1800 RPM vs. 700-2100 RPM
100%
50%
110%
1000600200 400 800100
Maximum TorqueMode
Expected MaximumEfficiency Mode
Output (kWe)
Fixed Speed Fuel Consumptionvs. Variable Speed
Economical Applications of VSG
• The economics of adding the VSG system will be better for applications with low average power demands
• Cranes that require full power for only short periods of time while lifting are good candidates
• With a VSG installed, the engine will idle most of the time, and increase in speed only when needed
IPS and Youtility
• Have designed a system that can be easily retro-fitted to existing RTG Cranes
• Several hundred existing cranes in service globally
• Youtility supplies electronic equipment, design responsibility and support to IPS
• IPS builds necessary electrical equipment, installation and project management
Typical RTG (Rubber Tire Gantry)
Basic VSG Diagram
VSGControl
ACSupply
Ultra-cap
Variable SpeedGenerator
Crane ACpower feed
800VDC
400 - 720VDC
290VAC - 36Hzto
480VAC - 60Hz
Detailed VSG Diagram
Pre-ChargeContactor
(+)
(-)
Rectifier Boost
OutputAC Inverter
Bypass / Isolation Contactors -Interlocked
Energy Store / ReleaseChopper control
Generator250kVA200kW480V
1800RPM
N
6.7L
153kW
EnergyStorage
Variable DC
Regulated 800VDC
Unique Features of Crane Electrical Power Requirements
• New Cranes use AC VFDs to power motors, the major loads (90%)
• AC VFD consists of a DC rectifier feeding DC power to an AC inverter
• Since the VSG also makes DC power, it can be fed directly on a “common DC bus”
VSG with common DC bus
VSGControl
AC VFDs
ACSupply
Ultra-cap
M M M
Variable SpeedGenerator
aux. loads
800VDC
400 - 720VDC
480VAC - 60Hz
290VAC - 36Hzto
480VAC - 60Hz
Detailed crane DC bus unit
Pre-ChargeContactor
(+)
(-)
Rectifier Boost
OutputAC Inverter
Bypass / Isolation Contactors -Interlocked
Energy Store / ReleaseChopper control
Generator250kVA200kW480V
1800RPM
N
6.7L
153kW
EnergyStorage
DC Bus powerconnection
Variable DC
Regulated 800VDC
Energy Storage Advantages
• Engine produces poor step change power at low speeds
• Energy Storage can supply full rated power in less than 4mSec. With DC/DC boost circuit
• Energy Storage can reclaim energy that otherwise goes to Dynamic Braking Resistors
• Energy Storage can “smooth” the power required from the generator, less peak required…therefore smaller generator
• For high cyclic loads, we prefer Ultra-Capacitors over batteries
A Maxwell brand Ultra-Capacitor
Energy Storage Calculations
• 48V x 144F each bank
• 16 banks in series = 768VDC x 9F
• Total energy = ½ * c * V 2 = 2.6MJ
• Useable energy = 0.7 x 2.5MJ = 1.75MJ
• Need 400kW (peak) – 150kW (engine) = 250kW x 7sec. = 1.75MJ
RTG Crane Expectations
• Overall Fuel Consumption reductions of 30% -50%
• Total Emissions reductions of 70% - 90%
• Reduce 23L engine to 6.7L engine
• Reduce Idling Fuel Consumption from 20+ L/hr. to 2 L/hr.
• We predict all future cranes will be VSG in less than 2 years, based on market competition
Other VSG Applications
• Most economical for variable load or less than full load applications
• Grid Connect, Stand Alone or Parallel Unit Operations
• Combined Heat-Power total efficiency for part-load conditions is much improved
• High power quality requirement applications
Other VSG System Features
• Transformerless output with full unbalanced load capabilities
• Synchronous Generator with integral field control, no need to use a different generator
• 96%+ pf. on generator, allows higher outputs with full VA rating utilized
• Integrated Energy Storage allows full step load changes in ¼ cycle, no freq. deviation
End of Presentation
• Bill YoungIndustrial Power Systems, Inc.
• Alan McDonnellYoutility Distributed Power Electronics