There are plenty of industrial diesel engines out
there running with "standard" IPs in constant speed
applications. The only real benefit to modifying the
pump for such an application would be to increase
longevity or reduce manufacturing costs.
The generator industry is full of what we commonly
called "assembled" units, meaning a supplier did
nothing more that purchase an industrial engine, an
alternator with voltage regulator, and a pre-packaged
set of engine controls. Flywheel housings are
standardized as are flywheels and couplings, so
there's almost no engineering involved. The tricky
part is the engine controls and governor.
The easiest and cheapest method of frequency (speed)
regulation is a mechanical, or flyweight governor.
There are only a few manufacturers out there, and
installation is pretty straightforward - you only need
a belt to drive it off the engine and linkage to
connect to the throttle.
The problem here is that mechanical governors, on a
good day, give you about 3% - 5% regulation. For
today's electronic devices, that's not very good. At
60Hz, +/- 5% is 57Hz to 63Hz. Your computer and other
frequency sensitive devices aren't going to be happy.
They may very well work, but you're on the ragged
edge. Take that down to 50Hz and the window opens up
even more.
There are lots of electronic governors out there, also
known as "isochronous" governors, which will maintain
a much tigher frequency (speed) regulation. However,
with tighter regulation comes higher costs. Companies
like Barber-Coleman and Woodward dominate this market,
and make many bolt-up,, off the shelf governor systems
that work independently of other engine/control
systems.
Another issue you run into when operating at the lower
end of the torque/horsepower curve is throttle lag.
Because you don't have the advantage of engine mass
working on your side like you would at a higher RPM,
variations from load to no load and vice-versa are far
more pronounced because of limitations in fuel system
operation.
A good example of this is the predecessors of solid
state UPS systems, which were nothing more than motor
generators (an electric motor, a big honkin' flywheel,
and a generator.) These not only provided a different
power source for mainframe computers (400Hz) but they
also acted as a UPS. The inertia stored in the very
large flywheel would continue to spin the generator
for several seconds when the motor was powered down
(power loss) providing power to the computers.
The flywheel also dampened response of the motor and
generator speeds. You could do much the same with an
engine generator if you wanted to put a monster
flywheel between them....
Anyway, I've rambled on enough as it is. Can you tell
I was in the business for 20+ years?
Dan
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