MITSUBISHI DIESEL ENGINE | !TEMNO.| — T60-0430-E (1/11) TECHNICAL INFORMATION — [pare March, 2008 Sudden Load Increase Characteristics (Transient Response) of SOB - S16R Generator Sets Definition of terms and design criteria for reciprocating intemal combustion engine driven alternating current generating sets are specified in the International Standard, ISO 8528-5 dated in April 1993, and Japanese Industrial Standards JISB 8009-5 “Generator Sets”, corresponding to the said ISO 85285-5, is established in December 2001 Both standards specify standard values of sudden load increase characteristics (operating limit values) of generator sets. This technical information explains the load increase characteristics specified in the above standards as well as those of generator sets with Sagami Diesel Engine. 1. Following factors particularly influence the transient frequency and voltage characteristics of the generating set, responding to sudden load changes. In other words, the sudden load increase characteristics of generator sets are affected by following factors: 1.1 Load Increase Load increase is affected by mean-effective pressure at rated power (Pme) supercharging system of engine (transient response of turbocharger), rated speed, exciting device characteristics and properties of voltage regulator of the generating sets, and moment of inertia of the entire generating sets. 1.2. Load Decrease Load decrease is affected by performance differences of govemors; electronic governors, hydraulic governors, and mechanical governors. 2, Responsibility for sudden load increase characteristics of generator sets demanded by Customers 2.1 Load increase and decrease characteristics of generator sets shall be subject to agreement between customer and manufacturer, which are specified in the above ISO and JIS standards. The manufacturers of generating sets are, therefore, responsible for load increase characteristics when providing generating sets to customers, For that reason, it is very important for manufacturers of generating sets to understand full extent of the ISO and JIS standards. Although those characteristics are greatly affected by engine characteristics, the manufacturers are still required to have ultimate control when making agreement with customers for the installation of generator sets. First Edition : Mar. 4th, 2005 Engine Engineering Department . lant Designing Section 8 ‘Approved by | Checked by [ Drawn by 2 aooss4 | 2005-214 ee S.Kiyokuni | H-Endo MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS AITEM NO, ‘T60-0430-E (2/11) 2.2 22.1 2.22 Calculation of generator set capacity for emergency power supply in the privately owned electrical power facilities under the Fire Defense Law (Applicable in Japan) The rated power required for emergency power supply installed in Japan shall be determined using the ‘equation stipulated in the Fire Code 100. (Power calculation software NH-1 Ver3 for privately owned electrical power facilities). Calculate the rated power required for generator sets and engines by: © Generator rated power G(KVA)2 RG X KX 0.95 (RG is maximum values of RG1-RG4 below) Where: RGI: Capacity to accept full load operation (constant load) RG2: Capacity to accept voltage drop on load increase (voltage drop) RG3: Capacity to accept starting current on load increase (over current capacity) RG4: Capacity to accept negative current by harmonic load (negative phase current) © Engine rated power E(KVA)2 1.36 x REx Kx CP (RE is maximum values of RE1-RE3 below) Where: REI: Capacity to accept load capacity on full load operation (Constant load) RE2: Capacity to accept speed changes on no-load (Speed changes) RES: Capacity to accept maximum power obtained during a short period of time engine operation (Maximum power) MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERSITEM NO. T60-0430-E (3/11) 3 ee gee Frequency characteristics (from ISO 8528-5, 5-3 Figure 4; Dynamic frequency behavior) Frequency recover tine B tre f : 3 ! \ os | U | f Ona Orn Frequency recovery time ° Time. Figure 4 — Dynamic frequency behaviour Fr: Declared frequency (rated frequency) (Frequency on declared power) Hz Fir Rated no-load frequency Hz fst: Frequency droop Ratio between the rated frequency and the difference between rated no-load frequency and rated frequency on rated power Sst = (Gr — fi) / rx 100 (%) fd,max: Maximum transient frequency rise (overshoot frequency) Hz Maximum frequency generated on sudden power changes on load decrease fa,min: Maximum transient frequency droop (undershoot frequency) Hz Minimum frequency generated on sudden power changes on load increase &fdyn: Transient frequency deviation from rated frequency % Sf "dyn: Ratio of the difference between the rated frequency and undershoot frequency on load increase (—) &f"dyn= (fi,min— fi) / fr X 100 (%) 8f"dyn: Ratio of the difference between the rated frequency and undershoot frequency on load decrease (+) Sf"dyn= (fd,max~fr) / fr X 100 (%) thde: Frequency recovery time after load decrease (sec) ‘fin: Frequency recovery time after load increase (sec) A£ Steady-state frequency tolerance band Hz (frequency band on steady-state frequency which brought to agreement) af Rated frequency tolerance band % (Ratio between stead-state frequency band and rated frequency) af = Af/frX 100(%) A £ Width of frequency oscillation v a BE Steady-state frequency band deviation % Bf = f / fr x 100 (100%) v MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS eeeITEM NO. T60-0430-E (4/11) 3.1 The steady-state frequency characteristics depend mainly on the performance of the engine speed governor. However, as specified in the above paragraph 1, the dynamic frequency characteristics on load increase/decrease (the response to load changes) depend on the combined behaviour of all the system components and thus on the individual design of all the relevant components. (ISO 8528-5, Para 5). It is very important to understand this characteristics since many customers have a misunderstanding that the dynamic frequency characteristics of the generator set depend on only engine characteristics. 3.2. The dynamic frequency behaviour (Fig. 4) on page 3 shows the required parameters for determining the sudden load increase specified in the ISO 8528-5. Limit values are classified by performance class of Gl - G3, which are shown on the table on page 5. As to class G4, the agreement between manufacturer and customer (“AMC”) is required. 3.3 Transient frequency deviation: Setting parameters for 5 f dyn (%) 3.3.1 The most influencing setting parameter for determining a sudden load increase is the transient frequency deviation 5 f dyn (%). However, many countries such as USA do not demand the 6 f dyn and make no setting at all. Only engine stop (s0 called engine stall) on sudden load increase is stipulated. In such case a sudden load increase is huge and a 100% load increase may be possible, Thus it is always important to confirm the setting conditions. 3.3.2 Rated frequency tolerance a f (%) affects frequency recovery time after load decrease (tf,de) as well as frequency recovery time after load increase (tf.in). These considerations are necessary when setting parameters since sudden load increase capacity changes as the result 3.4 Engine turbocharging system and sudden load increase characteristics 3.4.1 The number of highly turbochargered engines are increasing more and more these days. Even turbcharged engines over a Pme of 20 kg/cm? rated output are installed on the generator sets. On the engine equipped with a large-capacity turbocharger, the turbocharger response characteristics are very important to improve the instant frequency deviation 6 f dyn (%) mentioned above. 3.4.2 For improvement of turbocharger transient response, such as performance matching point change with engine (applicable to low speed torque specification), turbocharger rotating mass decrease, parallel ‘configuration of turbochargers, and application of variable geometry turbocharger are effective methods. 3.5. Voltage regulator, exciting device characteristics and sudden load increase characteristics of generator sets 3.5.1 Load on engine can be reduced by lowering generated voltage of generator at frequency drop due to sudden load increase, which is achieved by changing the AVR (automatic voltage regulator) characteristics from constant voltage mode to variable voltage/frequency mode. By reducing load on engines, transient frequency deviation 5 f dyn (%) can be improved so that apparent sudden load is increased, and frequency recovery time is reduced as well. 3.5.2. For power supply of operating machines, on the contrary to the above 3.5.1, especial excitation control is provided to secure the voltage of generator set on sudden load increase (for 0.2 to 0.3 seconds) to prevent ‘MC (electromagnetic contactor) trip on load increase by motors. In this case, the actual load increase is 20 to 30% of voltage setting. Substantial consideration is required for these load increase conditions. (MC: To cut the power of motor to protect operating machine motors in the event of voltage decline.) MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS(S11) T60-0430-E ITEM NO. Table 3 — Operating limit values ‘Bajes jeurwou > > oF os 21010 % 08 PUE %4 Gz UBeMIOg = Pe EO ifuveNs semod annoy | crt st o> munvcu 110 % coh PUB % 08 LeMIeG oie ony ‘a mvonenpow eBexon | erat a> vane ra? a prPtin Asonoses obenon | stot poz—> pse—> ‘a ye6ee7ou nod vappne = +> x ‘Bewes59p somo WEPANE % OOF ee oe azo ‘upiee eberon jo abu 19 Seu st ‘umes ebevon 10 ebuee we we a ‘uerequn ebeuEN, E> ‘ObF> id Sez> “SES vopenep ebeyon seis Apeais z z se uea save 1 Kaventen poreiou | _€St pe> os vo > Araaane1 Kounabo) oe> as> oor ales est ‘s0e—> est—> a ets aoe ones (@99t82:0U1 s2Mod vappns Aovonton pores wou | 9, ote at ae ‘eresep JOO VOPDNE He OOF Sate wCR+D—> | oCeton—> | »C+sn—> (a p2t¥9s2U1 emo vepons ‘Aovanba1 ent woHs ote Er wt ‘See; s9m0d Uapene 1% oor PoMEeUP As¥enbow worRuELL voice ‘umes Kavanbeny 30 abuewa jo ey friend Bujies Asuonbes puendn jo eb peIeIee Chasa< ‘umes Aouonbesy pienuMop Jo eOues pare o> ast> st> zat o> s> > ‘ooip foverbava | Veh 9 79 © seep souruoyog sonyen yy Gumeed ameuried Operating limit values by performance classes (ISO 85285-5, Para 16 and JIS 8009-5, Para 16) 4. 7-5 From ISO 8582-5; 1993 (E) MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS anITEMNO. | —_T60-0430-E (6/11) 5. Estimation of sudden load increase of generator sets with Sagami Diesel Engines S6B to SI6R. 5.1 The following figure shows the allowable load increase when transient frequency deviation (mentioned in paragraph 3) is specified to 6 f dyn S10 (%) Allowable load increase by governor types (test result on DG sets) © Mechanical Governor A Hydraulic Governor [1 Electric Governor Ys] 100 eas & [a0] = 3 leo} 8 2 Guide line required at first stage o 3 ISO 8528-5 and JIS = [ao : < [20 : 8.0 10) 12 4 16 18 20 Average effective pressure at rated power (Pme: kPa) 5.2 The above figure shows the test results of the generator sets manufactured by Mitsubishi Heavy Industries, Ltd. (MHD using O, A, and symbols. The test parameters are as follows: Frequency droop: 5 fst = 3.4% ‘Transient frequency deviation: 5 fdyn S 10%. Frequency recovery time after load increase: thin S 8 sec. Related frequency tolerance band: af S 1% Note that MHI takes deferent parameters (operating limit values) from those specified by ISO and JIS, 5.3. The guide line obtained from the MHI test shown above can be used to estimate the transient load increase characteristics for 1500 rpm and 1800 rpm generator sets manufactured by MHI. (Note that the above figure includes test results of 1000 rpm and 1200 rpm generator sets as well. Those data were also utilized to obtain guide line of 1500 and 1800 rpm engine.) 5.4 For estimating load increase characteristics for 1000 rpm and 1200 rpm generator sets, use the guide line of ISO and JIS shown above. The guide line of ISO and JIS can apply to all the engines of S6B - SI6U. MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS 7-6ITEM NO. 760-0430-E (7/11) 6, Estimation method of sudden load increase characteristics on base load of generator sets with Sagami diesel engines 6.1 Tests for allowable load increase on base load have been conducted on variety of engine models so that various data are available. The chart below is a simple method using those test results and empirical rules to estimate sudden load increase. D, D’ : Racket output (110%) BF + Rated output (100%) @ + Allowable oad increase on no-load t (Gérclative to rated output) wz 80 : [ex.S12A2-PTA 8 Pme=15kPa 2 at 1500min"* a i 3 E s [ex S12U-PTK| Pme=20.3kPa at 900min"* ime 2 100 110 (Operating output before load increase) kWe : % —> 6.2 Drawing method of above chart to estimate sudden load increase 6.2.1 From test results, find A point, that is the sudden load increase a , when the base load is zero (0), 62.2 Determine B point by multiplying a by 0.25 and draw a line from A to B. Find C, where a vertical line from the 50% of base load axis meets the A-B line. Draw a line from C point to the rack set t, D point. Then find E point where the C-D line meets the B-F line. 623 Obtained line, A-C-E-F, is possible sudden load increase curve. 6.23 Broken line (~———) in the chart shows the sudden load increase characteristics on base load obtained by SI2A-PTA, 1500 rpm engine. 62.4 The sudden increase characteristics of S12U-PTK, 900 rpm engine (Pme= 20.3 kPa) at rated output) is shown with the line with dots (— + + — + + — + + —) for reference. 6.2.5 Test conditions (parameters) of above 6.2.3 and 6.2.4 are the same conditions used for generator sets manufactured by MHI as specified in above 5.2. 63 Assen inthe chart above, sudden load increase at the first stage needs to be set at over 60% of rated output in order to get full load increase (100%) in two stages. From that, a 75% or more load increase for first stage setting may be required for $12U, 900 rpm engines. MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS 7-1ITEM NO. T60-0430-E (8/11) 7 7. 7, Staged sudden power increases characteristics required by ISO 8528-5 and JIS 8009-5 Brake mean-effective pressure (Pme): When Pme is high, a sudden power increase, in general, is required to apply in several stages. Guide values for maximum possible sudden power increases as a function of brake ‘mean effective pressure at declared power within allowable frequency drop on sudden load increase are specified in the ISO as well as JIS standards. The figure shown below is from ISO 8528-5: 1993 (E) 100 ! 90 t { 80 t } i . i i t 3 ie i ' 1 Ho + | t | H | iat power stage | FE uo I t : + t t : 35 30 t ; t i | i | 2 : i : | tt i a 1 ioe 1 eal [a i } ae 8 10 35 15 18 2a 2s. 30x 10? Mean tfectve pressure, Py of cared power, in Mopascls —e= Figure 6 — Gulde values for maximum possible sudden power Increases as a function of brake mean effective Pressure, ny. at declared power (four-stroke engines) 2. The number of times of staged sudden power increase is subject to the agreement between manufacturer and ‘customer in accordance with ISO. 3 The generator sets with S6B-S16U Sag: iesel engines sufficiently meet those requirements of ISO and JIS explained above paragraphs 5 an 7 if the specifications and equipment configurations of generator sets are standard. However, customers often demand performance more than required by ISO standards by comparing with other company’s generator sets (engines) at their inital inquiry. Thus general considerations often become necessary as to those characteristics specified above paragraphs 5 and 6. MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS: : -8ITEM NO. 160-0430-E (9/11) 8. Transient frequency deviation on load decrease 8.1 The following figure shows the transient frequency deviation on full load decrease obtained from the tests on the generator sets manufactured by MHI. Transient Frequency Deviation on Full Load Decrease by Governor Type O Mechanical Governor A Hydraulic Governor 1 Electric Governor 12.0 L T 3 10.0 3 A. 5 L 3 [ao ie oO = [6.0 r Mechanical Q| § 5 a) [LOH Hydeaute =a Electric 2.0) 7 8.0 to] _|fa2]|_ fag 16 18 20) Brake mean-effective pressure at rated power Pme : kPa 8.2. Transient frequency deviation on sudden load decrease as shown above mainly depends on the governor performance, that is, depends on types of governors. There are mechanical governors (Bosh, RUSV type), hydraulic governors (Woodward, PSG type) and electronic governors. (TOHO, Woodward 2301, and ABC, Dyna 8000) and the transient frequency deviation is being improved in that order. MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS aeITEM NO. T60-0430-E (10/11) 9. Inertial mass of generator sets affecting transient frequency deviation 9.1 As mentioned in the paragraph 1, the moment of inertial of the entire generator set has an influence on the transient frequency characteristics (speed changes) on load increase, The influence by the moment of inertial is considered here. 9.2 The following characteristic equations are applied. Energy E, the difference between load torque and torque generated by engine, is calculated as follows: Where: li: Inertial mass of entre generator set No: Speed before load increase Nui Minimum speed afterload increase Te: Torque generated by engine Load torque Torque T- Speed N-> 2 2 . 2n 2 Ny E=li [ 6 Ne] leo) Nu} Since Energy E is the same regardless of li changes, the following equation is 2 L1x( No! -Nu? )=12x(No —Nu2 ) in 163 Nul_) 2 T2 No Convert the obtained value to transient frequency deviation by: Nu2 No. 6 f dyn -[10- J x 100 % MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERSITEMNO. | —T60-0430-E (11/11) 9.3. Results of calculation obtained from the equation of above paragraph 9.2. Jee 100 Trea Maes Ratio x y z res 1.0 [Nem 10% 15.0% | 20.0% qe = Ll Ae? 9.0% 13.5% | 18.0% 42 B12 12.3% | 16.3% Se = 13 Noe = 7.6% 11.3% | 15.0% qh =14 Sexe =7.0% | 10.5% | 13.8% 9.4. The figure shown is the result of calculations: Influence by Inertial Mass on Transient Frequency Deviation 20 . Tt 10 4 pL 5 1.0 Ld 1.2 13 14 ‘Transient frequency deviation % —> Inertial mass (engine + generator set) increase MITSUBISHI HEAVY INDUSTRIES, LTD. GENERAL MACHINERY & SPECIAL VEHICLE HEADQUATERS