12/16/20151 generator basics jim siffring, product manager – generators

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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 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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12/16/20151 generator basics jim siffring, product manager – generators

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