Electric power generation professional development project

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Parts interaction with generator sales at Gregory Poole Power Systems

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  • Here at GPEC Power Systems we offer power generation to meet the customers need. While there are many products and services offered today we are going to focus on the generators offered by Caterpillar through GPEC\n
  • Caterpillar and Olympian offer generators in various shapes and sizes depending on what the customer needs. The three MAIN types of fuel sources used are Diesel, LP, and NG but Landfill Gas and Solar turbines are also available. \nThe engines offered in these sets range from 19hp to 21724hp and not all sets utilize CAT engines. The Olympian product line offers engines from Ford, Chevrolet, Perkins, and in the past has included International. \nThe generators power ratings range from 12ekw which would be for small applications such as homes all the way to 2000ekw for large facilities and even up to 6250ekw in large power plant operations. \n
  • There are three basic Operating Ratings for which generators are offered. Standby, Prime, and Continuous. There is another for parallelling situations, but this will not be discussed today. Understanding which Operating Rating is needed for a specific application is vital for proper sizing of the genset to meet the customer’s needs along with repair and maintenance parts supply. \n
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  • A rating of Standby is the most common. This is for emergency back up where the unit is going to run for less than 500hrs/yr and the load will vary between 60-80%. Typically these units will only run for a few hours at a time during events like power outages where power is expected to return promptly. \n\nOutput available with varying load for the duration of the interruption\nof the normal source power. Average power output is 70% of the\nstandby power rating. Typical operation is 200 hours per year, with\nmaximum expected usage of 500 hours per year. Fuel stop power in\naccordance with ISO3046\n
  • Prime Power\nOutput available with varying load for an unlimited time. Average power output is 70% of the prime power rating. Typical peak demand of 100% of prime-rated ekW with 10% of overload capability for emergency use for a maximum of 1 hour in 12. Overload operation cannot exceed 25 hours per year. Prime power in accordance with ISO8528. Fuel stop power in accordance with ISO3046.\n\nThese generators are typically used for a peak shaving application where a municipality wishes to offset utility customer demand (during Peak useage hours) with generators tied to the utility grid. These units will be started and supply varying amounts of load for an area to keep the utility grid from being overloaded. \n
  • Output available without varying load for an unlimited time. Average power output is 70 - 100% of the continuous power rating. Typical peak demand is 100% of continuous rated ekW for 100% of operating hours. Continuous power is in accordance with ISO8528. It is important to note that no overload capability pushes this application of generator to be in a a stable load demand environment. Typically, where there is no motor cycles starting or stopping. \n
  • Olympian Generators offer diesel, LP, and NG fuel source generators. These units can be found in light and medium duty applications where 600VAC or less is needed to be produced in single or three phase configurations. These gensets are offered as open units, with enclosures, or as packages with base tanks. Typical Olympian base tanks are in 12 – 24 hr capacities meaning that the generator would be able to run for that length of time producing the advertised electrical rating. These tanks are double walled and meet all applicable UL listings needed. The LPG/NG gensets are packaged by Generac for Olympian and offer the Generac controller which is reported to be able to parallel, which isn’t typical within the generator market for products between 75ekw and 200ekw. The diesel Olympian generator comes with either a Perkins “Perkapillar” and once reaching the 150ekw range are CAT engines. \n
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  • One challenge of PM parts for generators falls into the duty rating of the unit: Standby, Prime, Continuous. Due to the differences of operational capability of these units oil filters, fuel filters, and air filters could be different. One unit may have racor filters where another just like with may not. But within the similar duty ratings PM parts could be shared across engine sizes… although quantities could be different. \n
  • Whether it is a truck, a D4B, a Tub grinder, or generator a 3406 is still a 3406 and the major components such as crank, piston pack, camshaft and even cylinder head could be shared across industry lines. The same goes for other models 3208, 3306, 3456, C15, C6.6, 3412, 3516, C175. There are components of these engines that will be readily available simply because of the amount of operational units still in existence. \n\nA problem for repairing high voltage generators and paralleling units is seen in the electrical aspect. The exciter, CT, PT, breaker, even voltage regulator in a HV unit is different than its medium or low voltage counter part. If a part is the same across all three a transformer has been added to make this component work. Due to the specialty nature of the HV and paralleling units these parts will probably non-stock. \n\nWith anything as the units age the availability of parts is going to get harder and harder to source and lead times will vary. A fuel injection pump on a 3208 is still available, but has to be built so lead time on that can be as high as 6 weeks. This needs to be sure to be conveyed to the customer. \n
  • The generator packages whether it be Olympian or Caterpillar will have similar parts. The fasteners on a CAT enclosure or even doghouse panels for a 3406 – 350kW unit are more than likely the same as a 400 or even 600kw 3456 or C15 until even if there are 5 years between them. This goes for things like Fuel fittings between base tanks and engine lines, oil drainage lines and crank case breather lines. \nThe exterior panels, insulation, and even dog house panels are what take the longest. If it is newer unit then one can be pulled off an assembly line order if that model is still in production, but older units will need to be fabricated. You could utilize outside sources to assist in this if CAT has a extremely long lead time. \nUnless a full serial number is used pinpointing the exact package piece needed could be difficult to add to that the drawings on SIS Web may not reflect accurately what the technician is seeing in the field. \n
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  • Electric power generation professional development project

    1. 1. Electric Power GenerationProduct Offerings: Generator Sets
    2. 2. Generators Caterpillar and Olympian Generators Engines offered in 19 – 21,724 horsepower Generator ratings: Diesel/LPG/NG 12ekw – 2000+ekw Large Gas sets (continuous): 75ekw – 6520ekw
    3. 3. Generator Ratings Standby Prime Continuous
    4. 4. Generator Ratings Standy: Emergency Back-up Power Less Than 500 hrs/yr. Varying Load (Load Factor 60-80%)
    5. 5. Generator Ratings Prime: Unlimited hrs/yr. (8000 hrs/yr.) Varying Load (60-80%) Overload Capability Available (10%) Used for “Peak Shaving” applications
    6. 6. Generator Ratings Continuous: Continuous Application (8000 hrs/yr.) Steady Load (Load Factor 90-100%) No Overload Capability
    7. 7. Olympian Product Ranges Single Phase and Three Phase electrical production Light and medium duty application – 600V or less Diesel base tanks offered in 12/24hr capacities LPG/NG units packaged for Olympian by Generac Larger diesel generators offer CAT engines
    8. 8. Caterpillar Generators Offers units for light, medium, and heavy duty use. Same engine and generator combination used in different kW configurations. Packaged similarities.
    9. 9. Parts Related Maintenance parts Repair Parts Package parts
    10. 10. Maintenance Parts: PM parts could be different between Standby, Prime, and Continuous PM parts – oil filters, fuel filters, air filters shared on multiple units and engine sizes
    11. 11. Repair Parts: Major components throughout popular models shared across industry lines High Voltage and Paralleling units – electrical parts likely non-stock Older generator parts stocked less and less – 3412, 3306, 3208 Different packager than CAT, for CAT branded units can cause delays in parts needed
    12. 12. Package Parts: Small parts common all Packages – fasteners, washers, fuel fittings, oil drain lines, CCB lines Long wait times for order fulfillment Can be difficult to identify on SIS Web.
    13. 13. QUESTIONS
    14. 14. THANKS!

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