Cummins Inc. · NYSE:CMI
Cummins — Technical Presentation (December 2020)
64 slides from Cummins's technical presentation, Dec 15, 2020
Slide 1: NFPA 110 Testing and Service Requirements for Standby Power Systems
NFPA 110 Testing and Service Requirements For Standby Power Systems PowerHour webinar series for consulting engineers Experts you trust. Excellence you count on. December 15, 2020 12:000pm Eastern Time / 9:00am Pacific Time (1 PDH issued by Cummins Inc.)
Slide 2: Welcome!
Welcome! Cummins PowerHour webinar series is designed to help our engineer partners to… ▪ Keep up to date on products, technology, and codes and standards development ▪ Interact with Cummins experts and gain access to ongoing technical support ▪ Participate at your convenience, live or on-demand ▪ E
Slide 3: Meet your panelists
Meet your panelists Cummins Instructor: Cummins Facilitator: Cummins Panelist: Michael Sanford John Chen Mariano Rojas Product Strategy and Sales Enablement Leader Technical Marketing Specialist Senior Sales Application Engineer Cummins Inc. Cummins Inc. Cummins Inc. Your local Cummins contacts: ➢ A
Slide 4: Disclaimer
Disclaimer The views and opinions expressed in this course shall not be considered the official position of any regulatory organization and shall not be considered to be, nor be relied upon as, a Formal Interpretation. Participants are encouraged to refer to the entire text of all referenced documen
Slide 5: Course Objectives
Course Objectives NFPA 110 Testing and Service Requirements For Standby Power Systems Standby power systems testing, and service is critical to the reliability of the system. This course will walk participants through site acceptance and in-service testing and will review best practices that will em
Slide 6: Key service requirements for major components in an emergency power supply system
What are some of the key service requirements for major components in a typical emergency power supply system? 6
Slide 7: Product Testing Overview
Product Testing Overview Why is standby power system testing Product Testing Process important? Prototype Testing ▪ There is no single performance test standard for standby power systems. ▪ Existing test standards may be incomplete Manufacturer Testing or may not address all potential failure modes
Slide 8: Prototype Testing Overview
Prototype Testing Overview Prototype testing… Product Testing Process ▪ Validates a complete product’s operating characteristics and limitations, as well as its ability to withstand “normally occurring abnormal events”. ▪ Will include potentially destructive testing you wouldn’t want to do on your c
Slide 9: Manufacturer Testing Overview
Manufacturer Testing Overview Manufacturer testing… Product Testing Process ▪ Validates the assembly of the generator set. ▪ Relies on prototype testing to establish baseline performance criteria. ▪ Establishes baseline performance criteria for subsequent site testing. ▪ Relies on a qualified manufa
Slide 10: Site Testing Overview
Site Testing Overview Site testing… Product Testing Process ▪ Validates the ability of the generator set to perform as installed. ▪ Relies on manufacturer testing to establish baseline performance criteria. ▪ Establishes baseline performance criteria for subsequent maintenance testing. ▪ Relies on q
Slide 11: Site Testing Expectations
Site Testing Expectations Cold Start Test ▪ Validation of generator set starting system, load readiness and operation of starting aids (coolant heater, lube oil heater, etc.). Full Load Acceptance and Operation ▪ Verification that the generator set can achieve full nameplate rating in one step and a
Slide 12: Site Testing Expectations
Site Testing Expectations Sound Performance ▪ Testing of the complete assembled product as it is installed on site accounting for all site variables. ▪ May be mandated by local AHJ. Engine Emissions ▪ Consult equipment manufacturer for testing and analysis recommendations. ▪ May be mandated by local
Slide 13: Maintenance Testing Overview
Maintenance Testing Overview Maintenance testing… Product Testing Process ▪ Addresses common failure modes of both a component and the complete power system through routine inspection and service. ▪ Relies on site testing to establish baseline performance criteria. ▪ Establishes baseline performance
Slide 14: Concept Check
Concept Check Factory testing validates the __________________ of the generator set while site testing validates the generator set’s ability to operate ____________. a) Installation, as configured b) Assembled configuration, as installed c) Prototype, when maintained properly d) Performance, in an e
Slide 15: Concept Check
Concept Check Factory testing validates the __________________ of the generator set while site testing validates the generator set’s ability to operate ____________. a) Installation, as configured b) Assembled configuration, as installed c) Prototype, when maintained properly d) Performance, in an e
Slide 16: Maintenance Testing Overview
Maintenance Testing Overview 8.1.1 The routine maintenance and operational testing program shall be based on all of the following: (1) Manufacturer’s recommendations (2) Instruction manuals (3) Minimum requirements of this chapter (4) The authority having jurisdiction Reprinted with permission from
Slide 17: Maintenance Testing Overview
Maintenance Testing Overview 8.1.1 The routine maintenance and operational testing program shall be based on all of the following: (1) Manufacturer’s recommendations (2) Instruction manuals (3) Minimum requirements of this chapter (4) The authority having jurisdiction Recommendation Require equipmen
Slide 18: Parts Availability and Maintenance
Parts Availability and Maintenance 8.2.4 Replacement for parts identified by experience as high mortality items shall be maintained in a secure location(s) on the premises. 8.3.2 A routine maintenance and operational testing program shall be initiated immediately after the EPSS has passed acceptance
Slide 19: Parts Availability and Maintenance
Parts Availability and Maintenance 8.2.4 Replacement for parts identified by experience as high mortality items shall be maintained in a secure location(s) on the premises. 8.3.2 A routine maintenance and operational testing program shall be initiated immediately after the EPSS has passed acceptance
Slide 20: Starting Battery Maintenance
Starting Battery Maintenance 8.3.6 Storage batteries, including electrolyte levels or battery voltage, used in connection with systems shall be inspected weekly and maintained in full compliance with manufacturer’s specifications. 8.3.6.1 Maintenance of lead-acid batteries shall include the monthly
Slide 21: Starting Battery Maintenance
Starting Battery Maintenance 8.3.6 Storage batteries, including electrolyte levels or battery voltage, used in connection with systems shall be inspected weekly and maintained in full compliance with manufacturer’s specifications. 8.3.6.1 Maintenance of lead-acid batteries shall include the monthly
Slide 22: Starting Battery Maintenance
Starting Battery Maintenance 8.3.6 Storage batteries, including electrolyte levels or battery voltage, used in connection with systems shall be inspected weekly and maintained in full compliance with manufacturer’s specifications. 8.3.6.1 Maintenance of lead-acid batteries shall include the monthly
Slide 23: Starting Battery Maintenance
Starting Battery Maintenance 8.3.6 Storage batteries, including electrolyte levels or battery voltage, used in connection with systems shall be inspected weekly and maintained in full compliance with manufacturer’s specifications. 8.3.6.1 Maintenance of lead-acid batteries shall include the monthly
Slide 24: Fuel Quality Testing
Fuel Quality Testing 8.3.7 A fuel quality test shall be performed at least annually using appropriate ASTM standards or the manufacturer’s recommendations. Reprinted with permission from NFPA 110-2016, Standard for Emergency and Standby Power Systems, Copyright © 2015, National Fire Protection Assoc
Slide 25: Fuel Quality Testing
Fuel Quality Testing 8.3.7 A fuel quality test shall be performed at least annually using appropriate ASTM standards or the manufacturer’s recommendations. Reprinted with permission from NFPA 110-2016, Standard for Emergency and Standby Power Systems, Copyright © 2015, National Fire Protection Assoc
Slide 26: Fuel Quality Testing
Fuel Quality Testing Diesel fuel quality critical to equipment operation. • Typical stable lifespan of diesel is 12 – 16 months in ideal conditions. (most EPSS installations are NOT in ideal conditions) • Diesel sulfur content reduction (ULSD) limits fuel’s anti-microbial properties. • Bio-diesel bl
Slide 27: Fuel Quality Testing
Fuel Quality Testing 8.3.7 A fuel quality test shall be performed at least annually using appropriate ASTM standards or the manufacturer’s recommendations. TIA 8.3.7.1 Diesel fuel maintenance and testing shall begin the day of installation and first fill in order to establish a benchmark for future
Slide 28: Typical guidelines for exercising a generator set
What are typical guidelines for exercising a generator set? 28
Slide 29: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 30: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 31: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 32: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 33: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 34: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 35: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 36: EPS Testing with Load
EPS Testing with Load 8.4.2 Generator sets in service shall be exercised at least once monthly, for a minimum of 30 minutes, using one of the following methods: (1) Loading that maintains the minimum exhaust gas temperatures as recommended by the manufacturer (2) Under operating temperature conditio
Slide 37: EPS Low Load Operation
EPS Low Load Operation Minimize EPS operation below 30% load to mitigate adverse maintenance interval impact. • “Wet stacking” may deposit unburnt fuel into engine exhaust system. • Low combustion temperature may increase soot formation and aftertreatment “fouling”. Consult EPS manufacturer or equip
Slide 38: Transfer Switch Operational Testing
Transfer Switch Operational Testing 8.4.6 Transfer switches shall be operated monthly. 8.4.6.1 The monthly test of a transfer switch shall consist of electrically operating the transfer switch from the primary position to the alternate position and then a return to the primary position. Reprinted wi
Slide 39: Transfer Switch Operational Testing
Transfer Switch Operational Testing 8.4.6 Transfer switches shall be operated monthly. 8.4.6.1 The monthly test of a transfer switch shall consist of electrically operating the transfer switch from the primary position to the alternate position and then a return to the primary position. Recommendati
Slide 40: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9 Level 1 EPSS shall be tested at least once within every 36 months. 8.4.9.1 Level 1 EPSS shall be tested continuously for the duration of its assigned class. 8.4.9.2 Where the assigned class is greater than 4 hours, it shall be permitted to terminate the test after 4 c
Slide 41: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9 Level 1 EPSS shall be tested at least once within every 36 months. 8.4.9.1 Level 1 EPSS shall be tested continuously for the duration of its assigned class. 8.4.9.2 Where the assigned class is greater than 4 hours, it shall be permitted to terminate the test after 4 c
Slide 42: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9 Level 1 EPSS shall be tested at least once within every 36 months. 8.4.9.1 Level 1 EPSS shall be tested continuously for the duration of its assigned class. 8.4.9.2 Where the assigned class is greater than 4 hours, it shall be permitted to terminate the test after 4 c
Slide 43: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.5 The minimum load for this test shall be as specified in 8.4.9.5.1, 8.4.9.5.2, or 8.4.9.5.3. 8.4.9.5.1 For a diesel-powered EPS, loading shall be not less than 30 percent of the nameplate kW rating of the EPS. A supplemental load bank shall be permitted to be used to
Slide 44: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.5 The minimum load for this test shall be as specified in 8.4.9.5.1, 8.4.9.5.2, or 8.4.9.5.3. 8.4.9.5.1 For a diesel-powered EPS, loading shall be not less than 30 percent of the nameplate kW rating of the EPS. A supplemental load bank shall be permitted to be used to
Slide 45: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.5 The minimum load for this test shall be as specified in 8.4.9.5.1, 8.4.9.5.2, or 8.4.9.5.3. 8.4.9.5.1 For a diesel-powered EPS, loading shall be not less than 30 percent of the nameplate kW rating of the EPS. A supplemental load bank shall be permitted to be used to
Slide 46: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.5 The minimum load for this test shall be as specified in 8.4.9.5.1, 8.4.9.5.2, or 8.4.9.5.3. 8.4.9.5.1 For a diesel-powered EPS, loading shall be not less than 30 percent of the nameplate kW rating of the EPS. A supplemental load bank shall be permitted to be used to
Slide 47: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.5 The minimum load for this test shall be as specified in 8.4.9.5.1, 8.4.9.5.2, or 8.4.9.5.3. 8.4.9.5.1 For a diesel-powered EPS, loading shall be not less than 30 percent of the nameplate kW rating of the EPS. A supplemental load bank shall be permitted to be used to
Slide 48: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.6 The test required in 8.4.9 shall be permitted to be combined with one of the monthly tests required by 8.4.2 and one of the annual tests required by 8.4.2.3 as a single test. 8.4.9.7 Where the test required in 8.4.9 is combined with the annual load bank test, the fi
Slide 49: NFPA 110 36 Month Testing
NFPA 110 36 Month Testing 8.4.9.6 The test required in 8.4.9 shall be permitted to be combined with one of the monthly tests required by 8.4.2 and one of the annual tests required by 8.4.2.3 as a single test. 8.4.9.7 Where the test required in 8.4.9 is combined with the annual load bank test, the fi
Slide 50: Concept Check
Concept Check Per NFPA 110 8.1.1, the routine maintenance and operational testing program shall be based on which of the following: a) Manufacturer’s recommendations b) Instruction manuals c) Minimum requirements of this chapter d) The authority having jurisdiction e) All of the above 51
Slide 51: Concept Check
Concept Check Per NFPA 110 8.1.1, the routine maintenance and operational testing program shall be based on which of the following: a) Manufacturer’s recommendations b) Instruction manuals c) Minimum requirements of this chapter d) The authority having jurisdiction e) All of the above 52
Slide 52: Maintenance Record Requirements
Maintenance Record Requirements 8.3.3 A written schedule for routine maintenance and operational testing of the EPSS shall be established. 8.5.1 Records shall be created and maintained for all EPSS inspections, operational tests, exercising, repairs and modifications. 8.5.2 Records required in 8.5.1
Slide 53: Equipment Remote Monitoring
Equipment Remote Monitoring Single point visibility to assets and site performance anytime anywhere. 54
Slide 54: Equipment Remote Monitoring
Equipment Remote Monitoring Single point visibility to assets and site performance anytime anywhere. 55
Slide 55: Equipment Remote Monitoring
Equipment Remote Monitoring Single point visibility to assets and site performance anytime anywhere. 56
Slide 56: Equipment Remote Monitoring
Equipment Remote Monitoring Single point visibility to assets and site performance anytime anywhere. Immediate notification of any critical or non-critical issues through automated emails and push notifications. 57
Slide 57: Equipment Remote Monitoring
Equipment Remote Monitoring Single point visibility to assets and site performance anytime anywhere. Immediate notification of any critical or non-critical issues through automated emails and push notifications. Access to historical performance data to any asset through reports and trending. 58
Slide 58: Equipment Remote Monitoring
When evaluating standby system testing plans, ask yourself… • What testing has been conducted on a prototype product that may not need to be replicated once the product has been installed? • Is the manufacturer able to successfully demonstrate product performance through prototype and factory testin
Slide 59: When evaluating standby system testing plans, ask yourself…
Course Summary NFPA 110 Testing and Service Requirements For Standby Power Systems Standby power systems testing, and service is critical to the reliability of the system. This course will walk participants through site acceptance and in-service testing and will review best practices that will empow
Slide 60: Course Summary
Additional Resources Cummins White Papers Maintenance is one key to diesel generator set reliability Rated power factor tests and installation acceptance of emergency and standby power systems The 10-second start: NFPA 110 Type 10 starting requirements for generator set applications Design for safet
Slide 61: Additional Resources
Q&A Please type your questions, comments and feedback in the Zoom Q&A window. After the PowerHour, a complete list of questions and answers will be published on powersuite.cummins.com. Michael Sanford John Chen Mariano Rojas Product Strategy and Sales Enablement Leader Technical Marketing Specialist
Slide 62: Q&A
Q&A Please type your questions, comments and feedback in the Zoom Q&A window. After the PowerHour, a complete list of questions and answers will be published on powersuite.cummins.com. Please complete the brief survey after exiting the webinar! Michael Sanford John Chen Mariano Rojas Product Strateg
Slide 63: Q&A
Closing Watch out for a follow-up email including: Upcoming PowerHour Webinars: ▪ A link to the webinar recording and copy of the presentation January: Specifying Power System ▪ A certificate issuing one professional development hour (1 PDH) Equipment for Water and Water Facilities Visit powersuite.
Slide 64: Closing
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