PRODUCT PRESENTATION MTU AIR-COOLED DIESEL GENERATOR SET (ADG) 28 – 152 kVA
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TODAY‘S AGENDA 01. Philosophy 02. Why Air-cooling? 03. Product Overview 04. Air-cooled Diesel Generator Set Ratings 05. ADG: The Technical Concept – Standard Scope 06. ADG: Value Proposition
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01 PHILOSOPHY MTU AIR-COOLED DIESEL GENERATOR SETS
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PHILOSOPHY.
Our job:
Providing reliable power for any power demand and any environmental conditions
Our motivation:
Enhancing our product portfolio to the lower power range with an unique solution Just like MTU diesel systems our aircooled gensets are: extra-ordinary reliable focused on our customers demands designed for easy maintenance
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02 WHY AIR-COOLING?
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WHY AIR-COOLING. MOST COMPACT DESIGN.
Aircooled engines need approx 1/4 less volume, because the cooler/radiator is left out Combination of exhaust manifold and silencer achieves a compact solution for exhaust system Air-cooled engines require only 50% of the airflow of a comparable watercooled engine, this leads to smaller dimensions for the air passage! Page 6 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
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WHY AIR-COOLING. TROUBLE-FREE COOLING SYSTEM.
Ambient air Integrated aircooling Simple direct solution Made for extreme environmental conditions – no water, no problems!
Water cooling = indirect cooling
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WHY AIR-COOLING? TROUBLE-FREE COOLING SYSTEM.
Water cooled
Air cooled
The cylinder and cylinder head cooling fins are resistant against blocking due to the larger clearances The high air-pressure and speed are cleaning the cylinder and cylinder heads automatically
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WHY AIR-COOLING? LESS BREAKDOWNS, HIGHER AVAILABILITY. Causes of Failure
Percentage
Lack of lubricant
33,9%
Lack of cooling water
25,1%
Water inlet in cylinder
13,1%
Loose mounting parts
5,7%
Damage of oil outlet gear
5,5%
Damage of combustion air inlet
4,2%
Frost
3,3%
Miscellaneous
9,2%
More than 1/3 of all engine breakdowns are caused by malfunctions in the water cooling system!
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WHY AIR-COOLING? LOW MAINTENANCE – LOW OPERATION COSTS. Repair can be done very often without dismantling the engine from the equipment (single cylinder heads) Reduced maintenance, only one cooling system No wear and tear inside the cooling air pipes through cavitation, no deposits in the system – like corrosion, no need for cooling water additives No anti-freeze necessary No timing belt in lower power range, which normally would need to be changed every 1000 hours within sandy conditions Solid gear wheels are timing the engine No water drain necessary, during maintenance of the cylinders heads (e.g. change of the cylinder head gasket) Therefore no risk of getting sand into the liquids and consequently into the system All types of air cooled engines are modular, only one type of cylinder for the whole family Page 10 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
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03 PRODUCT OVERVIEW
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PRODUCT OVERVIEW
MTUDieselsystems
kVA
28 - 152 kVA PRP
50 80 90 100 125 150 175 200 225 250 275 300 350 400 450 500 550 600 650 700 750 800 900 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500
ADG
275 - 3 000 kVA PRP
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04 AIR-COOLED DIESEL GENERATOR SET RATINGS
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AIR-COOLED DIESEL GENSET RATINGS. AVAILABLE RAITINGS.
Output PRP / LTP Fuel consumption at 100% load* Sound Pressure at 7m*
ADG 28
ADG 32
ADG 42
ADG 62
ADG 102
28 / 31 kVA
32 / 35 kVA
42 / 46 kVA
60 / 66 kVA
99 / 109 kVA
144 / 152 kVA
6,5 l/h
7,1 l/h
9,3 l/h
13,9 l/h
22,1 l/h
31,8 l/h
62 dB(A)
62 dB(A)
64 dB(A)
63 dB(A)
66 dB(A)
66 dB(A)
*reference ratings for PRP only
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ADG 152
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05 ADG: THE TECHNICAL CONCEPT STANDARD SCOPE
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STANDARD SCOPE ADG. READY TO USE FOR ISLAND OPERATION. Engine: Deutz Series 912 (ADG 28) or Series 914 (ADG 32 – ADG 152) Fuel consumption optimized Alternator: ACG Voltages: 380/220 V, 400/230 V, 415/240 V Fuel System: Fuel-main filter & Fuel pre-filter with water separator Base frame: with integrated fuel tank Sound-proof canopy: with integrated exhaust system Controller: for Island operation Main circuit breaker + generator breaker Starter battery & 12 VDC battery charger Single lifting point Oil drain valve Standard air filter 2010 Page 16 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
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STANDARD SCOPE ADG. READY TO USE FOR AMF* OPERATION. Engine: Deutz Series 912 (ADG0028) or Series 914 (ADG0032 – ADG0152) Fuel consumption optimized Alternator: ACG Voltages: 380/220 V, 400/230 V, 415/240 V Fuel System: Fuel-main filter & Fuel pre-filter with water seperator Base frame: with integrated fuel tank Sound-proof canopy: with integrated exhaust system Controller: for AMF operation Main circuit breaker + generator and mains breaker Starter battery & 12 VDC battery charger Single lifting point Oil drain valve *AMF = automatic mains failure 2010 Page 17 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
Standard air filter
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TECHNICAL CONCEPT. WELL KNOWN ENGINE – DEUTZ 91x SERIES. Highly robust engine 100% load acceptance for natural aspirated engines (ADG 28 – ADG 42) More than 4 million engines sold world-wide High service availability
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TECHNICAL CONCEPT. LOW MAINTENANCE ENGINE. Modular engine design – only one type of cylinder – only one type of spare part for the whole engine family Oilfilter:
Injector:
replace 500 hours
check 3000 hours
Fuelfilter:
Valve-clearance:
replace 1000 hours
check 1000 hours
No timing belt – solid gears for valve timing
Cooling system check: depending on application
Oil change: 500 hours
First major overhaul: 12.000 h
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TECHNICAL CONCEPT. ALTERNATOR – DESIGNED TO OUR SPECS. Customized ACG alternator designed to our specifications Voltages @ 50 Hz: 380V/400V/415V 3-phase, 12-lead, 4-pole synchronous alternator IP23 2/3 pitch winding Auxiliary winding – 300% short circuit current capability Compliant to I.E.C 60034-1; BS 4999-5000; NEMA MG 1.22; C.S.A C22-2; VDE 0530 and GB755 Standards Approved continuous operation stability Page 20 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
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TECHNICAL CONCEPT. ALTERNATOR – DESIGNED TO OUR SPECS. Windings Hand-wound end-windings – higher copper density Triple insulated and vacuum pressure impregnated windings Rotor Separately balanced excitation winding – reduced vibrations Improved cooling – stepped leads & axial ventilation drillings Improved efficiency due to exact balanced rotor Bearings High quality bearings made in Germany Handling Access to the voltage regulator without opening the terminal box Splited air vent for easy dismantling and convenient access to the diodes Page 21 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
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TECHNICAL CONCEPT. AIR CONDUCTION. Main issue with air-cooled gensets: Cooling air flow No re-circulation of warm air
Solution: Air ducts to control the flow of the different air streams
Fresh air
Hot used air from alternator
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Hot used air from engine
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TECHNICAL CONCEPT. CANOPY PARTITIONS. Main issue with air-cooled gensets: Cooling air flow No re-circulation of warm air
Solution: Partition walls to separate the canopy in cold and hot areas
Cold area Page 23 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
Hot area
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TECHNICAL CONCEPT. CONTROLLER – USER & SERVICE FRIENDLY. World-wide known end established Deep Sea Controller Easy parameterization No special interface necessary for parameterization – Connection to PC via standard USB cable Clear text display
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TECHNICAL CONCEPT. CONTROLLER – APPLICATIONS. 1.) Island Operation (E1) The island operation of the ADG controller already features the remote start ability.
2. ) Automatic Mains Failure (AMF) operation (E2) The genset will automatically start in case of a mains failure and supplies the load with emergency power.
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TECHNICAL CONCEPT. ATS – FULLY INTEGRATED. Fully integrated Automatic Transfer Switch (ATS) – two electronically interlocked Circuit Breaker for Automatic Mains Failure Operation (AMF) No handling of additional accessories One point of installation Highest mobility, because everything is included in one package
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TECHNICAL CONCEPT. LIGHTWEIGHT DOORS. Highest protection against various weather and ambient conditions Modern industrial design Safe and simple handling because of low weight Large doors – optimized accessibility for service activities Double-walled design – excellent sound insulation Environmentally friendly – 100% recyclable
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TECHNICAL CONCEPT. EASY MAINTENANCE AIR-FILTER. Rectangular air filter Placed in the middle panel Easiest access for service purposes Low cost Filter service indicator Shorter combustion air conduction & air filter located outside of the gen set lower air intake temperature into the engine
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TECHNICAL CONCEPT. EASY MAINTENANCE– OIL DRAIN POINT. Easy oil draining due to oil drain valve in the base frame No complicated handling of an oil drain pump or an additional hose Clean and most comfortable way to drain the oil Most time efficient for small oil amounts (up to 20l) During the time the oil needs to drain off other service works can be done
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TECHNICAL CONCEPT. EASY MAINTENANCE – BATTERY. Easiest access – only two screws have to be removed The battery is not placed at a hardly accessible place inside the canopy The battery is placed fully isolated – a damage of the battery will not affect other systems
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TECHNICAL CONCEPT. SINGLE LIFTING POINT.
Easy access to lifting point via hatch with magnetic lock Only one lifting point – uncomplicated handling with lifting gear
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TECHNICAL CONCEPT. BASE FRAME FUEL TANK. Light-weighted PET fuel tank Capacity: 155 liters for ADG 28 – ADG 62 240 liters for ADG 102 & ADG 152
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TECHNICAL CONCEPT. MECHANICAL FUEL LEVEL GAUGE. Robust Less failures than electronic fuel level gauges Easy to read No complicated navigation through the genset controller menu for fuel level checking
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TECHNICAL CONCEPT. EXHAUST ON THE TOP. The main criticism of our customers is now eliminated Higher flexibility for the selection of the installation location No more inconvenience due to exhaust gases around the genset The exhaust is conducted to the roof without negative effects on the temperature inside the canopy
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06 ADG – VALUE PROPOSITION
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ADG. VALUE PROPOSITION. Low operational costs Trouble free cooling system Low maintenance engine & improved service points (e.g. oil drain, air filter)
Designed for extreme environmental conditions Air-cooled
High reliability & durability Robust engine Alternator with proven continuous operation stability
Minimized logistics costs – compact design Easiest handling for operators and for service Easy access to filters, voltage regulator Userfriendly controller Page 36 / MTU Onsite Energy Systems GmbH / 3/21/2013 © MTU Onsite Energy Systems GmbH / All rights reserved
THANK YOU FOR YOUR ATTENTION © MTU Onsite Energy GmbH All rights reserved
