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Efficient Operation of Diesel Generator Sets in Remote Environments

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Efficient Operation of Diesel Generator Sets in Remote Environments Efficient Operation of Diesel Generator Sets in Remote Environments Kaitlyn R. Wheeler Thesis submitted to the faculty of the Virginia Polytechnic Institute and State University in partial fulfillment of the requirements for the degree of Master of Science In Mechanical Engineering Alfred L. Wicks, Chair Douglas Nelson Steve C. Southward May 9, 2017 Blacksburg, VA Keywords: mobile hybrid power system, fuel consumption, energy storage, diesel engine, generator © 2017, Kaitlyn R. Wheeler i Efficient Operation of Diesel Generator Sets in Remote Environments Kaitlyn R. Wheeler Abstract Diesel engine and generator sets (gensets) have been extensively used for standby and remote power generation over the past hundred years. Due to their use for standby power, these diesel gensets are designed to operate in conjunction with the grid, which relates to a fixed speed operation with a 60 Hz AC output. For operation in remote conditions, such as military and disaster relief applications, this fixed speed operation results in limiting the power output available from the engine, as well as the overall efficiency of the system. The removal of this grid connectivity requirement could result in an increase in system efficiency. At a given load, the engine operates more efficiently at lower speeds, which corresponds to an increase in the system efficiency. This low speed operation also results in lower power output. Knowledge of the load is important in order to determine the most efficient operating point for fixed speed operations. Operating at a higher power output for a given speed also results in higher system efficiency. The addition of a battery pack will allow for a higher apparent load, resulting in higher operating efficiency. The addition of a battery pack will also allow for energy storage, which allows for a higher operating efficiency, as well as “engine off time”. A controlled series capacitor converter should be used to ensure that the maximum power is transferred from the genset to the battery/load. Knowledge of the load and equipment available should be used in order to determine the ideal dispatch strategy. Overall, operation at the grid frequency limits the efficiency of the overall system for remote operations where grid frequency is not required. The simulated genset had an efficiency of 24% for a 3 kW when operated at 1800 RPM, and increase from the 17% efficiency at it normal operating speed of 3600 RPM. This corresponded to a fuel savings of 3 gallons over 24 hours of continuous operation. When a battery is incorporated into the system, the efficiency of the system will increase for a given output load. For example, the simulated genset has an efficiency of 15% for a 1 kW load, which increases to 24% when a battery is added and charged at 2 kW. ii Efficient Operation of Diesel Generator Sets in Remote Environments Kaitlyn R. Wheeler General Audience Abstract Diesel engine and generator sets (gensets) have been extensively used for emergency and remote power generation over the past hundred years. Due to their use for emergency power, these diesel gensets are designed to operate in the same way as the grid. This results in a fixed speed operation in order to achieve 60 Hz. For operation in remote conditions, such as military and disaster relief applications, this fixed speed operation results in limiting the power output available from the engine, as well as the overall efficiency of the system. Increasing the efficiency of the diesel engine will increase the overall system efficiency, which is the relationship between the energy into the engine as compared to the energy produced. At a given load, or energy output requirement, the engine will operate more efficiently at lower speeds. This low speed operation, however, will result in a lower power output. Therefore, knowledge of the load is important in order to determine the most efficient operating point for a diesel engine, and the genset as a system. Operating at a higher power output for a given speed also results in higher system efficiency. The addition of a battery pack will allow for a higher apparent load, or the load seen by the engine, resulting in higher operating efficiency for the engine. The addition of a battery pack will also allow for energy storage, which allows for “engine off time”, or time which the system can provide power silently. Analysis should be conducted to ensure that the maximum power is transferred from the genset to the battery/load. Knowledge of the load and all equipment available should be used in order to determine the ideal charging and discharging strategy for the battery and system. Overall, operation at the grid frequency limits the efficiency of the overall system for remote operations where grid frequency is not required. A simulation was conducted to illustrate this concept. The simulated genset would save approximately 3 gallons of fuel over a 24 hour operating time when run at of speed of 1800 RPM, as opposed to its normal operating speed of 3600 RPM. When a battery is incorporated into the system, an additional gallon of fuel can be saved over a 24 hour period. iii Acknowledgements I would first like to thank Dominion Power and the Marine Warfighting Laboratory for providing the funding and support for my research. I would like to thank my committee for their guidance through both my undergraduate and graduate careers here at Virginia Tech. Dr. Wicks, who has supported me though this research and created a very welcoming lab, Dr. Nelson, who first sparked my interest in engines and the automotive industry, and Dr. Southward, who has supported my interest in controls. I would like to thank my parents, Matt and Jill, my brother, Joey, and all my extended family for their complete support throughout all aspects of life. Without this love support, I never would have reached the point at which I am today, both academically and as a person. I would like to thank my fiancé, Tommy, for being with me every step of the way and supporting my decisions. He has kept me sane throughout this process. Finally, I would like to thank the members for the Mechatronics Lab, Virginia Tech, and Fairfax County Public Schools. I am here today due to the support, guidance, and academic foundation each has provided me. iv Contents ABSTRACT II GENERAL AUDIENCE ABSTRACT III ACKNOWLEDGEMENTS IV LIST OF FIGURES VIIII LIST OF TABLES IX CHAPTER 1 OVERVIEW 1 1.1 Introduction 1 1.2 The Grid 2 1.3 Diesel Engines 4 CHAPTER 2 LITERATURE REVIEW 6 2.0 Chapter Overview 6 2.1 Variable Speed Gensets 6 2.2 Battery Discharge Strategies 11 2.3 Maximum Power Transfer 14 CHAPTER 3 MODELING 24 3.0 Chapter Summary 24 3.1 Engine Modeling 24 3.2 Generator Modeling 29 3.3 Overall Genset Efficiency 32 CHAPTER 4 SIMULATION AND VALIDATION 33 4.0 Chapter Summary 33 4.1 Engine Simulation 33 4.2 Genset Simulation 37 4.3 Simulation of Genset at Varying Operating Speeds 40 4.4 Battery Use at Varying Operating Speeds 41 4.5 System Design 45 CHAPTER 5 SUMMARY 47 Chapter 5.0 Chapter Overview 47 Chapter 5.1 Modeling Conclusions and Next Steps 47 Chapter 5.2 Genset Operation for Increased Efficiency 47 v Chapter 5.3 Summary 49 REFERENCES 50 vi List of Figures Figure 1. Example of a genset efficiency curve [1]. 2 Figure 2. Example of grid layout [2]. 2 Figure 3. First diesel engine patented by Rudolph Diesel in 1892 [8]. 4 Figure 4. Example of a diesel engine power-speed curve. A genset with four pole generator operating at 50 or 60 Hz with result in an operating speed 1500 or 1800 RPM, limiting the available power out of the engine. [10]. 7 Figure 5. Example of a diesel engine torque-speed curve. A genset with two pole generator operating at 50 or 60 Hz with result in an operating speed 3000 or 3600 RPM, increasing the fuel consumption for a given load [10] Use of this engine with a 4 pole generator, or operating at 1800 RPM, would allow for operation at its most efficient point. 7 Figure 6. Block diagram for simple permanent magnet variable speed diesel generator [8]. 9 Figure 7. Block diagram for variable speed diesel genset developed for the US Army [9]. 9 Figure 8. Operation of variable speed and constant speed genset operation under various environmental conditions [12] 10 Figure 9. Charging profile for a UCharge battery with a charging rate of C/2. Charging can be is done at constant current up to 90% SOC. After this point, the battery is charged at a constant voltage until the battery reaches 100% SOC [27]. 12 Figure 10. Full charge of sample battery using 2 kW generator with 1 kW load. 13 Figure 11. Full charge of sample battery using 5 kW generator with 1 kW load. 13 Figure 12. Partial charge (SOCmax = 80%) of sample battery using 5 kW generator with 1 kW load. 14 Figure 13. Simple Thévenin circuit. 15 Figure 14. Power to load ratio as a function of load/source ratio. The maximum power to the load occurs when the load resistance is equal to the source resistance. 16 Figure 15. (a) Thévenin equivalent circuit of a permanent generator [30]; (b) Thévenin equivalent circuit of a battery. The equivalent resistance must be equal to that of the diesel generator equivalent resistance for maximum power transfer [31]. 17 Figure 16. Example of alternating current and voltage vs time [29]. 17 Figure 17. Power triangle for AC circuits relating the real power (P), reactive power (Q), and apparent power (VrmsIrms) [29].
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