12/16/20151 generator basics jim siffring, product manager – generators
TRANSCRIPT
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Generator Basics
Jim Siffring, Product Manager – GeneratorsJim Siffring, Product Manager – Generators
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Generator Makeup – Major Components
Engine (mechanical energy)
Alternator (electrical energy)
Cubicle (control/monitor/breakers)
Governor (engine speed for frequency)
Voltage regulator and excitation system
Cooling System (heat removal)
Skid base & fuel tank
Canopy with lifting bale
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Build-up of a generator
Engine Power = kW Alternator Power = kVA
Power connections
Engine speed
related to the frequency
AVR
related to the output voltage
AVR
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Prime, Standby, Continuous
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Standby? Prime? Continuous?
Generator Set Rating Depends on– Engine Rating
Duty Cycle, Altitude, Temperature
Standards define engine performance
– Alternator Rating
– Cooling System Capacity
– Installation Design
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Standby Generators Applicable for supplying emergency power for the duration of a utility
outage. Should be applied where reliable utility power is available and may not be run in parallel with the public utility, except for closed transition transfers. Requires an ATS (Automatic Transfer Switch) or some other type of electrical switchgear.
UL2200
UL 149
High Spec
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Automatic Transfer Switch (ATS)(Standby application)
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Standby Generator Rating
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Continuous Base Power
Applicable for supplying power continuously to a load 100% of the base rating for unlimited hours
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Prime Power
Applicable for supplying power in lieu of commercially purchased power.
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Prime Power Applications
Construction– General site power– Lighting– Electric tools– Welding– Hoists, lifts, cranes– Pumps
Chem. & Petro Industry– Turnarounds– LACT units– Truck loaders– Instrument testing– Drilling/production/transportation
Manufacturing– Equipment testing– Peak shaving– High load starting (demand charge)
Telecom– Cell tower maintenance– Temporary equipment
Electric Utilities– Transformer maintenance– Line disconnections
Events– Music– Races
Absence of Utility Power– Remote locations– Utility service inadequate
Disasters– Storm / hurricanes– Earthquakes– Terrorism
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Portable Generators
Production facilities Generators
Zaragoza, Spain
Rock HillUSA Wuxi,
China
Sao PauloBrazil
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Strategy
High Quality
Fully Featured
Reasonable Price
Serviceability– Single side maintenance
– 500 hour intervals
– Large access doors
– Fluids plumbed to edge of skid
– Heavy duty fenders on trailers
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Portable Generator Market
Frequent movements
Wide range of applications
Harsh conditions
Sound attenuation
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QAS 25 - 600
The Big
Performance
Versatility
Service Efficiency
Transportability
Resale Value
Key Benefits
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QAS 25 - 120
QAS 25-45 QAS 70-90-120
PRP @ 480V / 60Hz kVA 25-45 70-120
Sound pressure level dB(A) dB(A) 67 - 68 67
Fuel autonomy Hours 24 24+
Spillage Free Frame Standard
Engine Brand Kubota John Deere
Rated speed rpm 1800
Alternator Brand Leroy Somer with AREP
Variants: Multi Voltage (240/480V)
122°F
-13 F
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QAS 150-600
QAS 150 QAS 250-330 QAS 600
PRP @ 480V/60Hz kVA 140 237-319 571
Sound pressure level dB(A) dB(A) 71 71-73 77
Fuel autonomy Hours 24 24 ~8
Spillage Free Frame Standard
Engine Brand John Deere Volvo Penta
Rated speed rpm 1800
Alternator Brand Leroy-Somer/AREP Leroy-Somer/AREP Leroy Somer/PMG
Variants: Multi Voltage (240/480V)
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Atlas Copco Generator Range, North America
MODEL ENGINE PRIME POWER
QAS 20 KD Single phase Kubota 17.3 kVA / 17.3 kW
QAS 25 KDiT4 Kubota 25 kVA / 20 kW
QAS 45 KDiT4 Kubota 45 kVA / 35 kW
QAS 70 JDiT4 John Deere 70 kVA / 56 kW
QAS 90 JDiT4 John Deere 94 kVA / 75 kW
QAS 120 JDiT4 John Deere 120 kVA / 95 kW
QAS 150 JDiT4 John Deere 150 kVA / 120 kW
QAS 250 JDiT4 John Deere 228 kVA / 183 kW
QAS 330 JDiT4 John Deere 330 kVA / 264 kW
QAS 600 V Volvo 571 kVA / 457 kW
QAC 1200 FLX Cummins 1200 kVA / 1000 kW
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Q A S 330 J D
EPA emission levelIT4 : EPA Tier 4 interim
SilencingS : SilencedC : ContainerizedX : Hardhat
Power (kVA)Continuous Power @ 60 HzBE CAREFUL WITH THIS!
Engine supplierD : DeutzG : Detroit DieselJ : John DeereP : PerkinsY : YanmarV : VolvoC : Cummins
Prime moverD : diesel engine
Altas Copco generator model # breakdown
IT4
Product rangeQ : Generator
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Generator Ratings
Same exact set may have different ratings
– Standby 100 kW 125 kVA 100%
– Prime 90 kW 113 kVA 90%
– Continuous 80 kW 100 kVA 80%
Prime Power is our best application!
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Generator Rating & De-Rating
Make sure you compare ratings correctly!
Altitude & Temperature effect output as well
Atlas Copco Ratings– Maximum Ambient Temperature
– Altitude
– Minimum Starting Temp (w/o assist)
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Generator Derating, Altitude and Temperature
Example - QAS 25
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AML Data
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Generators – kW vs kVA – 3 Phase
277/480vac Wye, 120/208vac Wye, 120/240vac Delta.
kW / .8 = kVA– Standby or Prime rating
All 3 phase generators are designed for a power factor = 0.8– Example : 100 kVA alternator
80 kW diesel engine
This means that the generator is used most optimal if the load has a power factor of 0.8
– At that time both engine power and alternator power can be used at 100%
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Generators – kW vs kVA – Single Phase 120vac, 240vac
kW = kVA– Standby or Prime rating
Single phase generators are designed for a power factor = 1.0– Example : 100 kVA alternator = 100KW
100 kW diesel engine
This means that the generator is used most optimal if the load has a power factor of 1.0
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U.S. Generator Competition(Construction & Rental Segment)
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Competition Matrix
Atlas Copco CP MQ - Whisper Watt Baldor Doosan CAT Magnum Wacker
20 - 30 kVA QAS 25 CPG 25 DCA 25* TS25T G25XQ20 XQ30
MMG 25G14 G25
31 - 40 kVA TS35T G40 MMG 3541 - 50 kVA QAS 45 CPG 45 DCA 45* TS45T XQ45 MMG 45 G5051 - 60 kVA TS60T XQ60 MMG 5561 - 70 kVA QAS 70 CPG 70 DCA 70* G70 G7071 - 80 kVA TS80T XQ80 MMG 7581 - 90 kVA QAS 90 CPG 90 DCA 85* G90
91 - 100 kVA XQ100 MMG 100 G100101 - 125 KVA QAS 120 CPG 120 DCA 125* MMG 120 G120126 - 150 kVA QAS 150 DCA 150* TS130T G145 MMG 150 G150
151 - 200 kVA TS175T G185 XQ175 MMG 170G160 G180
201 - 300 kVA QAS 250DCA 220 DCA 250
DCA 300TS250T
G240 G290
XQ230 XQ300
MMG 235 G240
301 - 400 kVA QAS 330 DCA 400TS350T TS400T
XQ400 MMG 320
401 - 600 kVA QAS 600 DCA 600 TS500TG450 G570
XQ600 MMG 405
601 - 800 kVA DCA 800*also available in Ultra-Silent
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Market Influences
Suppliers– e.g. Engine, alternators: 55 – 65% of product cost
– Large players
– Exposure to material prices fluctuations Increasing prices (copper / steel )
– AC is small player compared to others Smaller buying power
– Huge market demand, suppliers are fully booked
– Supply flexibility not always OK
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Market Influences
Competition– Many players:
Low End High End International / regional / local Different character per region
– Well established brands– Huge production volumes: economy of scales– Broad product range– Vertical integration: engine / alternator / canopy– Market coverage: Sales & distribution channels– Multiple production sites– Lower profit-targets
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Super Silent Range:– 7 kVA – 800 kVA
– Less expensive
– Not as quiet as Ultra Silent
Ultra Silent Range:– 25kVA – 150kVA
– 11% quieter than SS
– More expensive
MQ claims to have about 50% of the on-site generator market
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MQ Power (Denyo)
Strongest selling features (Super-silent):– Lower price than the Ultra Silent– Outstanding reputation for quality and reliability– Very simple controls– Low sound levels– Full environmental containment. (recent improvement)– 24 hour integrated fuel tank.
Disadvantages:– Alternator insulation is Class F i.s.o. Class H.– Remote start/stop is optional on the DCA 25 and DCA 45 (Standard for
Atlas Copco).– Trailers are of lesser quality than Atlas Copco.
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MQ Power (Denyo)
Strengths
50+% Market Share
Locally built in KY
2 versions– Super-Silent
65 dba
– Ultra-Silent (11% quieter) 58 dba
Weaknesses
Tend to be expensive
Trailers added in TX
Tenuous relationship with Denyo
Scrapped container line
Down from estimated 70-80% market share
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MQ Power (Denyo)
Struggling somewhat– Support is slipping
Management changes– Understaffed
Still the “generator of choice” in the market– Ships lots and lots each month
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MQ Power (Denyo)
Released IT4 versions to market
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Magnum
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Flip-Hood!
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Magnum
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Magnum
Strengths
Low cost / low FCP
Small company (330 employees)
#1 Light Towers, #2 Generators & #3 Pumps
Military business
Weaknesses
Bought by Generac– Integration challenges
– Fills void for Generac
– Identical product to Generac
Path to Market different– Generac – Large dealer
network
– Magnum – Focus on direct sales
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Mangum
Over-rating on specs– MMG 75 is 72 kVA prime
– MMG 100 is 98 kVA prime
– MMG 120 is 116 kVA prime
Low quality housing
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Strengths
Strengthening & growing– #2 provider at Sunbelt
– Signing smaller dealers
Aggressive marketing
10 models – 25 to 570 kVA
Weaknesses
Korean name - unknown
Large, bulky units
Product support
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Doosan
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Wacker
Strengths
Diverse product line
10 models– 14 to 240 kVA
– Cold weather option
Weaknesses
Weak dealer support
Unusual color
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Wacker
Gaining momentum
Regional Generator Sales Specialists– Attacking rental market
Most national rental Companies– Bread & Butter business
– Sunbelt, Hertz, Neff, etc
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MMD
Strengths
Pricing
Acceptance in Market
Weaknesses
“Dying”
Expensive, poor support
Izusu engines / Taiyo alt’s
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HiPower (Himoinsa)
Strengths
Ready To Rent line
Large product line– 21 models (25 to 700 kVA)
Gaining in popularity– Hertz & United
Aggressive pricing
Using DeepSea
Weaknesses
Himoinsa name– Now HiPower
Unknown brand
Poor quality
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Caterpillar
Strengths
CAT name
XQ models– Starts at 200Kw
9 containers– 500 to 5200 kVA
Weaknesses
Not core business
Expensive
2nd tier competitor
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Caterpillar
Tough on dealers – want all Cat generator business
Releasing new models– Very quiet
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Strategy
Synergy– Synergy with
compressor businesshuge customer base
– Extend our offeringTotal solution
– Increase customer share
Positioning– Dedicated
portable applicationproducts
– Target market
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Atlas Copco Generators Features & Benefits
– Solid doors & housing
– 110% fluid containment
– Quick fuel disconnects
– Fuel filler & vent tubes
– Sound baffling – special coating & epoxy
– Heavy-duty trailer & jack
– Lighting package grommeted in place
– Galvaneal coating under powder coat paint
– Single breakers with CT protection
– 2 x 50 amp Hubbell receptacles
– 30 micron & 5 micron fuel filters
– Locking potentiometer
– Analog gauges
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Portable Generator Products – QAS
QAS“Made for versatility”
– High Quality Power
– Multi-Voltage
– Very Sturdy Design
– Environment & safety
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Committed to Sustained
Productivity.
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