Redesign of kW Diesel Products Reflects Voice-of-The-Customer Improvements

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1 When Your Credibility Depends On It - Connect With Us Volume III, Issue 1V December 2012 In This Issue: Redesign of kW Diesel Products Page 1 University of Utah Install is MPS Showpiece Page 2 New Spark Ignited Engines Mean Longer Life Page 4 IBC 2009 and 2012 Seismic Certification Page 5 Redesign of kW Diesel Products Reflects Voice-of-The-Customer Improvements Generac Industrial Power once again highlights its commitment to continuous improvement with the latest release of the 400/500/600kW diesel industrial configured generators. This dramatic new refresh applies to single and paralleled emergency and standby solutions. This product line improvement is the direct result of going out to our customers and listening to their needs and wants, said Paul Bowers, Vice President, Industrial sales. Taking customer feedback to heart, Generac established redesign goals to make installation easier, support stricter code requirements, ensure reliability and maximize performance. This generator redesign reduces installation labor by elevating the generator breakers, providing more room for cable regrouping. Repositioning the breakers means cables run straight into the breaker bays for connections, with or without gland plate conduit termination. The alternator connection boxes also offer optional main lug connections in either of the circuit breaker bays for easier selective coordination. Generators can be configured with a single output breaker on one side and a set of main lug connections on the other side for easy load bank access. continued on page 3 1

2 University of Utah Install is MPS Showpiece Two other issues to be addressed were space, which was a critical issue in the yard where the generators were installed, and sound levels. After giving their MPS presentation and producing a schematic that showed how the MPS solution would fit the footprint and meet the noise criteria in the spec (the Gemini units were quieter at the outset than the competitive product), Generac and EMC were awarded the job. Several organizations affiliated with the University of Utah in Salt Lake City have their data protected thanks to a Generac MPS installation that will scale from the current 5 MW to 11MW. It is a success that exemplifies how dealer teamwork yields more. With an engineer in one territory and the job site in another, teamwork paid off with an exceptionally large project, and a Generac MPS showpiece. The five Gemini units on the one bus were installed and commissioned in The other six units are slated to be installed in the near future as needed. A 22,000 gallon diesel fuel tank serves the five Gemini units, and a separate such tank will be installed with the other six units. While the fuel storage and delivery system was designed by the engineering firm, EMC worked closely with them on all aspects of system integration. Generac MPS systems provide up to 9 megawatts per bus, but this installation needed more. The Generac team was able to work with the customer to meet their needs by installing two separate MPS systems on two separate buses. Comprised of a total of 11 Generac Gemini diesel backup generators five on one bus and six on another this installation backs up the data centers for both the University of Utah and University of Utah Hospital. Reliability was absolutely critical in this installation, as it is in all data center applications, said Curt Gibson, power solutions manager, Generac. This is an N+2 system that achieves a reliability of five nines, which exceeds Uptime Institute s Tier IV certification. And despite the number of nodes and unique approach, we were able to do it more cost effectively and with a smaller footprint than the competitive solution. Originally the spec had required large 2 megawatt single-engine nodes connected in parallel using traditional switchgear. Gibson and Energy Management Corporation (EMC), the Generac Industrial Dealer Central (IDC) of Utah, worked with the engineering firm and electrician in Salt Lake City to present the value of integrated paralleling. Our MPS solution reduced costs by eliminating the custom paralleling controls, Gibson said. That was a very attractive differentiator. The electrical contractor working on the project also had familiarity installing Generac s Gemini generators, and was able to document how the installation of the Gemini units would reduce labor costs compared to competitive systems. The lack of external switchgear coupled with the more readily available Gemini units also helped to significantly reduce the lead time required for installing the units. Early completion of the project allowed the university to move into the data center ahead of schedule. This truly was a team effort, Gibson said. The university s project manager had great confidence in EMC. He was impressed by the fact that EMC was the only dealer in his experience who was on site when the generators arrived. This installation has helped to demonstrate to other customers the value of MPS systems for large megawatt backup power. Gibson said that one of the worlds major online retailers has purchased a similar system for their call center in the Salt Lake valley, and other data centers have been influenced by this project. 2

3 Redesign of kW Diesel Products continued from page 1 Modifications also address stricter local code interpretations that call for the separation of circuits inside the connection box. And to minimize exposure to arc flash potential, all control wiring is isolated in a termination box away from power cabling Generac continues to raise reliability standards. A new and innovative upward radiator discharge hood provides protection against circulating air discharge, prevailing wind issues, hot muffler heat rejection, and physical damage to the radiator. Placing the muffler in the discharge hood is optimal for system reliability and aesthetics, said Rick Lincoln, Director of Engineering, Generac. This genset configuration also improves vibration isolation and damping. The entire engine and alternator are isolated from the frame using IBC seismic certified vibration dampeners. This allows all the supporting equipment to be rigidly mounted to a seismically reinforced and vibration damped frame, said Lincoln. The most noticeable change in the line-up is integrating the Perkins diesel engine. The 400kW to 600kW Generac generators are now powered by the Perkins 12.5L, 15.2L and 18.1L engines. Working with an established strategic diesel engine partner allows Generac to deliver higher performance and proven reliability. The Perkins engines are EPA certified low emission. They feature electronic fuel injection and are engineered for fast start-ups and optimized transient loading. One of our goals with this redesign is to maximize generator performance. Our customers in mission-critical applications have voiced their desire to start and parallel a multi-megawatt generator system within ten seconds. These engines give us that capability, said Bowers. Even as Generac continuously seeks new efficiencies and enhancements, these new diesel generators rely on the same trusted G-200 and H-100 PowerManager Controllers used throughout the industrial products line. Of course, each of the new generators will retain all of its configurable options and meet all regulatory compliances, including UL, NEC, NFPA, and IBC 2009 and 2012 seismic certification. Most importantly, these changes demonstrate Generac s dedication to the very highest standards of quality and reliability for their industrial diesel products. MD600kW, Diesel MPS Genset 3

4 New Generac Spark-Ignited Engines Mean Longer Life, Shorter lead Times The popularity of gaseous fuel in commercial and industrial power applications continues to grow. Applying natural gas and LP-fueled engines to generators, however, requires considerable engineering skill to ensure reliability and long life. With more than 20 years of in-house engine design expertise, Generac Power Systems has designed and manufactured two new gaseous-fueled engines specifically for use in several Generac industrial power systems. Generac s 80kW and 100kW generators now feature the new Generac 9.0L Engine, with the Generac 150kW through 275kW generators now powered by the new Generac 12.9L Engine. Gaseous fuels behave very differently than gasoline in a sparkignited engine, and that means making significant modifications to the engine, says Peter Winnie, director of engineering at Generac. The fuel system has to be replaced or converted. The valve train must be hardened to withstand wear and higher temperatures. Engine timing needs to be addressed. By designing and building our own engines, we can ensure that every challenge is met and that every generator meets the high standards of reliability our customers expect, especially in mission-critical applications. In manufacturing its new engines, Generac used stainless steel for the intake and exhaust valves to ensure durability and long life. Stellite, an extraordinarily tough cobalt-chromium alloy, makes the valve seats resistant to corrosion and wear. As dry-fuel engines lack the benefit of the lubricating qualities of liquid fuels, Generac reduced the valve angles from 45 to 30%, thereby minimizing the added friction that results from using gaseous fuels. The pistons are made of hypereutectic, cast aluminum to resist thermal expansion for tighter clearances that result in quieter operation and longer piston-ring life. Manufacturing its own engines also helps Generac ensure that it can deliver products with the shortest lead-times in the industry. Generac 9.0 Liter Engine Generac prides itself on short manufacturing lead-times, says Paul Bowers, Generac Industrial Power s vice president of sales. One way we achieve this is through vertical integration. Manufacturing these new 9.0L and 12.9L engines ourselves gives us additional control over our products and allows us to meet our customer s demands more effectively. Each of the generators using one of the new Generac engines will retain all of its current features and configurable options, and will ship from the factory in full compliance with all regulatory requirements. And like all of the company s industrial generators, it is fully compliant with IBC 2009 and 2012 seismic standards. Generac 12.9 Liter Engine 4

5 Seismic Certification Allows for Wider Range of Applications, Greater Flexibility in Installation and Site Placement Waukesha, Wis., December 7, Generac industrial-configured products are part of an elite offering of the most durable, powerful, emergency and standby generators available, meeting or exceeding the latest and most stringent standards for seismic certification and suited for the strictest building requirements as set by the International Code Council. Recently issued IBC code standards now classify critical equipment such as generators as a component of the building s structure that must remain operational following an event where the building sustains a seismic force. Generac products are fully certified to meet all published editions of IBC 2009 and 2012 seismic certification from the California Office of Statewide Health Planning and Development (OSHPD) SDS level 2.0 (for diesel-fueled products) and 2.5 (for spark-ignited products.) Certification on these products also includes rooftop applications, allowing a far greater degree of flexibility in installation and site placement than ever before, reaffirming Generac s status as a premier manufacturer of top-quality, industrialconfigured power products. 35kW, 5.4L Gaseous 25kW, 2.4L Diesel 300kW, 13.3L Gaseous 350kW, 12.9L Diesel Shaker Table Testing performed at the US Army ERDC-CERL facility in Chanpaign, IL (left top & bottom photos), and at QualTech NP in Cincinnati, OH (right top & bottom photos) 5