GENERATOR COOLING AND ENCLOSURE VENTILATION SYSTEM

A system for cooling a generator includes a generator system. The generator system includes a generator, an enclosure, the enclosure surrounding the generator, and a radiator, wherein the radiator is fluidly connected to the generator. The system also includes a radiator and ventilation fan system. The radiator and ventilation fan system includes a controller. The radiator and ventilation fans system also includes a ventilation fan variable frequency drive (VFD), the ventilation fans VFD in electrical communication with the controller and a ventilation fan in electrical communication with the ventilation fans VFD. In addition, the radiator and ventilation fan system includes radiator fans VFD in electrical communication with the controller and a radiator fan in electrical communication with radiator fans VFD. Further, the system includes temperature sensors, the temperature sensors in electrical communication with the controller.

TECHNICAL FIELD/FIELD OF THE DISCLOSURE

The present disclosure relates generally to generators, and specifically to cooling generators and generator enclosures.

BACKGROUND OF THE DISCLOSURE

Generator systems, particularly those within enclosures, have traditionally required cooling to avoid overheating and to maintain proper fluid temperature within the radiator. Overheating of the generator system can result in premature shutdown, damage to mechanical components, and reliability risks for motors and fans. Failure to maintain proper fluid temperature within the radiator can result in suboptimal performance of the generator of the generator system.

SUMMARY

In an embodiment, a system for cooling a generator is disclosed. The system includes a generator system. The generator system includes a generator, an enclosure, the enclosure surrounding the generator, and a radiator, wherein the radiator is fluidly connected to the generator. The system also includes a radiator and ventilation fan system. The radiator and ventilation fan system includes a controller. The radiator and ventilation fan system further includes a ventilation fan variable frequency drive (VFD), the ventilation fan VFD in electrical communication with the controller and a ventilation fan in electrical communication with the ventilation fan VFD. The radiator and ventilation fan system also includes a radiator fan VFD in electrical communication with the controller and a radiator fan in electrical communication with a radiator fans VFD. The system also includes temperature sensors, the temperature sensors in electrical communication with the controller.

In another embodiment, a method for cooling a generator includes supplying a radiator and ventilation fan system, the radiator and ventilation fan system. The radiator and ventilation fan system includes a controller. The radiator and ventilation fan system further includes a ventilation fan variable frequency drive (VFD), the ventilation fan VFD in electrical communication with the controller and a ventilation fan in electrical communication with the ventilation fan VFD. The radiator and ventilation fan system also includes a radiator fan VFD in electrical communication with the controller and a radiator fan in electrical communication with a radiator fan VFD. The radiator and ventilation fan system also includes temperature sensors, the temperature sensors in electrical communication with the controller, the temperature sensors including a jacket water engine temperature sensor, an enclosure temperature sensor, and a charge air temperature sensor. The method also includes communicating a value measured by the enclosure temperature sensor to the controller and based on the value measured by the enclosure temperature sensor, changing the voltage or frequency of the power input to the ventilation fan using ventilation fan VFD to achieve a predetermined set point for enclosure temperature.

DETAILED DESCRIPTION

FIG.1is a block diagram of generator system100. Generator system100includes generator110surrounded by enclosure130. Generator110may be fluidly connected to radiator120. In certain embodiments, radiator120is outside enclosure130. In other embodiments, radiator120is inside enclosure130. In certain embodiments, radiator120is a stacked core radiator or a split core radiator. In these embodiments, the first of the cores of the radiator cools water circulated through internal passages in the generator110to extract and carry away some of the heat produced by the combustion cycle, referred to as jacket water. The second of the cores of the radiator cools a cooling fluid, such as water, that cools the generator air intake air after it is pressurized by the turbocharger. This dual radiator core cooling system may be referred to as separate circuit after-cooled or SCAC.

FIG.2depicts radiator and ventilation fan system200. Radiator and ventilation fan system200includes controller210. Controller210may control the ventilation fan variable frequency drive220(referred to hereinafter as ventilation fan VFD220) and variable frequency drive for the radiator fan230(referred to hereinafter as radiator fan VFD230) based on temperature inputs from temperature sensors240. In other embodiments, controller210may control a radiator fan VFD controller and a ventilation fan VFD controller. Certain non-limiting examples of temperature sensors240may include jacket water engine temperature sensor242, one or more enclosure temperature sensors244, and charge air temperature sensor246. Controller210may be in electrical communication with temperature sensors240, ventilation fan VFD220and radiator fan VFD230. Ventilation fan VFD220may control one or more electrically-powered enclosure ventilation fans260by varying the voltage and frequency of the power input, which results in a change in the motor speed of enclosure ventilation fans260. In other embodiments, a single ventilation fan VFD220may control a single ventilation fan260, thereby being a ventilation fan VFD220for each ventilation fan260. Similarly, radiator fan VFD230may control one or more electrically-powered radiator fans270by varying the voltage and frequency of the power input, which results in a change in the motor speed of radiator fans270. In other embodiments, a single radiator fan VFD230may control a single radiator fan270, thereby being a single radiator fan VFD230for each radiator fan270.

By changing the motor speed of enclosure ventilation fans260, the enclosure air temperature may be maintained at a set point between, for example and without limitation, −50° F. and 200° F. In certain embodiments, the frequency of the power input to ventilation fans260may be between 5 Hz and 60 Hz. By changing the motor speed of radiator fans270, the operating temperature of the cooling fluids for the generator may be maintained at a set point between, for example and without limitation, 0° F. and 250° F. In certain embodiments, during operation of generator110, radiator fans270are in operation.

Controller logic of controller210may depend on the operating parameters of generator system100and radiator and ventilation fan system200. In a non-limiting example, during startup of generator system100, controller210may not recognize any faults or inputs, such as inputs from temperature sensors240until the generator is running at a predetermined set point, such as 1000 RPM or greater and for a predetermined time, such as at least 15 seconds. Once these conditions are met, controller210reviews all inputs including any faults or alarms. Upon detection of a fault, controller210may make several attempts to clear the fault. If the fault cannot be cleared, controller210may send a shutdown command to the controls of generator110. In the alternative, if the fault cannot be cleared controller210may send an alarm to an operator or cause ventilation fan VFD220and/or radiator fan VFD230to operate at maximum speed. Further, in this embodiment, during operation of generator system100, controller210may monitor charge air temperature sensor246. Depending on the value returned by charge air temperature sensor246, radiator fans270may be controlled using radiator fan VFD230. For example, when charge air temperature sensor246has a low value, such as 90° F., radiator fan VFD230may set the speed of radiator fans270to 10% fan speed. In addition, for example, when charge air temperature sensor246is at a high value, such as 130° F., radiator fan VFD230may set the speed of radiator fans270to 100% fan speed. Radiator fan VFD230may also set the speed of radiator fans270based on jacket water engine temperature sensor242. For example, when jacket water engine temperature sensor242returns a low value, such as 160° F., radiator fan VFD230may set the speed of radiator fans270to 10% fan speed. In addition, for example when jacket water temperature sensor returns a high value, such as 195° F., radiator fan VFD230may set the speed of radiator fans270to 100% fan speed. In certain embodiments, controller210may compare the value of charge air temperature sensor246and jacket water engine temperature sensor242. Controller210may communicate to radiator fan VFD230the speed of radiator fans270based on the percentage of maximum input value, i.e., if the value returned by charge air temperature sensor246is closer to its maximum input temperature than the value returned by the jacket water engine temperature sensor242, controller210may set the speed of radiator fans270based on the value of charge air temperature sensor246. In yet another example of the embodiment, depending on the value returned by enclosure temperature sensor244, enclosure ventilation fans260may be controlled using ventilation fan VFD220. For example, when enclosure temperature sensor244has a low value, such as 70° F., ventilation fans VFD220may set the speed of enclosure ventilation fans260to 10% fan speed. In addition, for example, when enclosure temperature sensor244has a high value, such as 110° F., ventilation fan VFD220may set the speed of enclosure ventilation fans260to 100% fan speed. During shutdown of generator110, when engine speed is below a certain predetermined value, radiator fan VFD230may set the speed of radiator fans270to 0% fan speed and ventilation fan VFD220may set the speed of enclosure ventilation fans260to 90% fan speed until a predetermined condition is met, such as enclosure temperature sensor244returning a value of below 110° F. or a time frame, such as one hour, is exceeded.