Type SpecificationsCHP Unit with Waukesha Gas Engine

for installation in engine room

(C) MOTORGAS 2012-10

INdoor MGW 500Natural Gas - emissions NOx < 500 mg/m3 @ 5%O2

Scope Specifications Technical Data Engine & Generator Control System Balance Data Cooling Device Requirements for the Construction Technical Diagram

Producer MOTORGAS s.r.o. Oderská 333/5 19600 Praha 9 Czech Republic www.motorgas.cz info@motorgas.cz

Scope Specifications

Compact CHP unit - consisting of modules to be connected on site

Gas engined generator set on steel base frameGas engine coupled with synchronous generator through elastic couplingEngine control and management (automatic AFR regulation included)Air filterGas mixerThrottle valveElectronic ignitionHeat Module - Equipment for heat production / coolingMain plate heat exchanger - engine coolingExhaust gas heat exchangerElectrical circulating pump - engine circuitSafety valve - engine circuitExpansion vessel - engine circuitCooling the filling mixture LT (technological circuit 54 °C)Radiator cooler for filling mixture coolingCirculating pump of mixture cooling circuitSafety valve mixture cooling circuitExpansion vessel -mixture cooling circuitGas lineGas filter

Zero gas pressure regulatorManometer - signalizing high / low gas pressureExhaust system - fully stainless steelInsulated flexible duct with heat-resistant textile material

Silencer Exhaust

Electrical SwitchboardControl system (separate description follows)Power section with integrated generator circuit breakerStarting batteries 24VDC with electronic charging with disconnecter

OPTIONS - per extra price

Equipment for connection to the heating circuitHeating circuit pumpReturn temperature control with three-way control valveEmergency cooling system to waste heat from engineEmergency radiator coolerEmergency circuit control equipmentAnti-noise coverAnti–noise cover with electrical motor driven ventilatoroptionally speed control of ventilatorOil filling equipmentThe central oil tank with optional volumeElectrical engine heaterOxidizing catalyst when required

Electric shut-off valves (2 pcs single or 1 pc of double valve)

Exhaust gas heat exchanger from stainless steel incl.heat insulation

Compensators

Technical Data

Fuel / Gas quality natural gasNominal fuel calorific value 35,8 MJ/Nm3

Type of Co-generation UnitProducerNominal electrical power output 500Nominal heating output VT 70 / 90 °C (kW) 674Nominal voltage - frequency - speedNominal power factor 1Operating gas pressure entering the CHP gas lineThermal gradient of heating systemFlow of water in the heating circuit (kg/s) 8,0

Exhaust Gas EmissionsCompliance with emission limits according to Czech Government Regulation No. 146/2007 Sb

500CO @ 5% O2 dry gas (mg/m3) 650NMHC @ 5% O2 (mg/m3) 150

NoiseNoise pressure level at distance 1m (without anti-noise cover) 97 +- 3 dB/A/Noise pressure level at distance 1m (with anti-noise cover) 75 +- 3 dB/A/

73 +- 3 dB/A/

INdoor MGW 500MOTORGAS s.r.o.

400 V - 50 Hz - 1500 rpm

2 - 3 kPa90 / 70 °C

NOx @ 5% O2 dry gas (mg/m3)

Exhaust noise pressure level at distance 5 m from outlet

Engine

Type of engine - turbocharged WAUKESHA L36 GLDNominal speedNumber of cylindersBore 152 mmStroke 165 mm

DisplacementAir - Fuel ratio / combustionLube oil filling quantitySpecific oil consumption at nominal power outputCompression ratio 11:1Engine weight (dry) 5080 kg

Generator

Type of generator - synchronousProducerNominal apparent powerNominal active power 522 kWNominal voltageClass F / 105 KPower factor operating range 0,8 – 1,0Nominal voltage - frequency - speedNumber of bearingsGenerator weight 1240 kg

96,4% - 96,4% - 96,2%

1500 min-1

12 V shape

36 dm3 (l)1,5 / lean burn174 litres0,3 g/kWh

Leroy Somer LSAC 49.1 M6EMERSON / Leroy Somer653 kVA

40 °C

400 V - 50 Hz - 1500 rpmdouble-bearing

Efficiency (p.f.=1) @ 100% - 75% - 50 %

Control System

CharacteristicOptimal configuration for single and multiple generating setsGenerators can operate in parallel or island mode (stand-by)The control system is equipped with a powerful graphic display.Intuitive control based on icons, symbols and bar graphs.The choice of three types of display panel:

Possibility of external modules for additional measurements or programming functions.

Display screens and pages structuresThe measured values

Alarm listHistoryHelp / othersStandard FeaturesAutomatic start / stop unit

Automatic generator synchronizing controlMains protection including vector shift, load and power factor control, earth faultprotection and the major functions providedMeasuring temperatures, pressures and levels of operating media (gas, water, oil)

Protection upon module or sensor failureGas leakage detectionWarning operator before exceeding limit value

Up to 8 users defined, each one with different access rights (levels of protection)Engine run hours and time to service counters

Communication InterfaceBI 16x, 16x BO, 4 AI, 1 AO, signals for external communication

Optional extensionRemote control via GSM GPRS networkFunction island mode of CHP - delivery of power during blackout

Basic: InteliSys panel - Full graphic display with black and white screenOptional: InteliVision 5 - full graphic display panel with 5.7 "color display, resolution 320 x 240 pxOptional: InteliVision 8 - full graphic display panel with 8 "color display with resolution of 800 x 600 px

Predefined configurations for typical applications are available as well as user-defined configurations for special applications

Create graphs of measured values (only in combination with InteliVision 8)Setpoints

Speed / power control

Measurement of electrical values (voltage, current, power factor, frequency)

Creating trends of measured values on the display (only in combination with InteliVision 8)Automatic shutdown in case of exceeding limit value

Export data to USB flash drive (only in combination with InteliVision 8)

Serial communication with the master control system via Modbus

Serial communication with the master control system other than Modbus protocol

InteliSys BaseBox – control unit

Panel InteliSys - basic display (with black and white graphics)

InteliVision 5 - full-color graphic display size 5.7 "

InteliVision 8 - full-color graphic display size 8 "

Balance Data Sheet

TIC 54 C NG NG NGL36GLD MGW 500 MGW 500 MGW 500%load 100,0% 75,0% 50,0%Fuel input [kW] 1390 1097 780 Mechanical power [kW] 519 389 260

10,00 10,52 11,25139,8 110,3 78,4

Generator efficiency 96,4% 96,4% 96,2%Electrical power output [kW] 500 375 250 Total heating power [kW] 674 549 403 Heat from jacket water [kW] 372 315 260 Heat from oil cooler [kW] 41 37 36

69 40 19 Heat from exhaust [kW] 261 197 107 Electrical efficiency 36,0% 34,2% 32,0%Heating efficiency 48,5% 50,0% 51,7%Total efficiency 84,5% 84,2% 83,7%

1591 1098Exhaust temperature [°C] 438 432 371

1,094 1,094 1,094Heat losses [kW] 56 44 31

35,8Outlet exhaust gas temperature [°C]Technical data based on ISO 3046Standard reference conditions

Tolerance for fuel consumption + 5%Tolerance for heating outputs data +-8%

500 kWe 375 kWe 250 kWeTotal efficiency 84,5% 84,2% 83,7%

36,0% 34,2% 32,0%

Fuel Input 100%

48,5% 50,0% 51,7%

Spec. fuel consumption [MJ/kWh]Fuel consumption [m3/hr]

Heat from intercooler LT [kW]

Combustion air [kg/hr] 2 118

Exhaust gas flow [kg/hr] 2 783 2 145 1 460 Cp exhaust gas [kJ/kg.K]

Caloric fuel value [MJ/m3]

Pressure 100 kPa, temperature 25°C, relative humidity 30%

Generator Power Output (kWe)

Electrical Efficiency

Heating Efficiency at 70/90 C

Loss

Emergency Cooling

GFH 067A/2x3-N(D)-F6/4P

Capacity 725 kW MediumAir flow Pressure drop 0.39 bar

Volume flow

Fans Noise pressure levelData per motor At a distance ofSpeedCapacity 1.63 kWCurrent 4.30 A

Tube volume 101 l Connections per unitWeight (dry) 589 kg Inlet 104.0*2.00 mm

Outlet 104.0*2.00 mm

Filling Mixture Cooling (Technological Cooling Circuit)

GFH 052A/2-N(D)-F6/4P

Capacity 79 kW MediumAir flow Pressure drop 0.28 bar

Volume flow

Fans Noise pressure levelData per motor At a distance ofSpeedCapacity 0.78 kWCurrent 1.35 A

Tube volume 22 l Connections per unitWeight (dry) 172 kg Inlet DN65/PN10

Outlet DN65/PN10

Drycooler

ethylene glycol 34 %(1)

77 600 m³/h41,76 m³/h

6 Kusů 3~400V 50Hz 66 dB(A)(2)

10.0 m1340 min-1

Drycooler

ethylene glycol 34 %(1)

14 400 m³/h14.69 m³/h

2 Kusy 3~400V 50Hz 57 dB(A)(2)

5.0 m1340 min-1

Requirements for design of CHP engine rooms construction

Placing and spaceMinimal free space from unit base frame on side of the unit 1500 mm (for both side)Minimal free space in front of electrical switchboard 1200 mmMinimal free space from side where piping connection 1000 mm

Requirement for engine room floor: dust free concrete or pavement

Ventilation of engine room

Oil handling equipmentOil tank is an option. Usually is mounted on the console on the wall of the machine room.

Setting of electrical switchboardSwitchboard is separated single mounted part.

Setting of emergency dry coolerOutside a) placed on concrete foundationb) placed on bracket mounted on building

Venting (degassing)

Exhaust pipinga) independent exhaust piping DN100 leaded over engine room

b) leaded into chimney – overpressure system required

Heating customer system (secondary circuit)Co-generation unit can be optionally equipped with secondary (heating) circuit water pumpThree way valve – controls return heating water temperatureSafety valves on primary and secondary circuits

Electrical equipment and power supply system

Arrange power outlet 3f+N+PE/16A close to the unit.

Other requirements and space demand Inlet gully for drainage from the exhaustFresh water including the washbasin in the engine room

Engine and generator are coupled and mounted on steel base frame with inserted anti-vibration elements. Transmission of the vibration is minimal. Normally there is no need to prepare anti-vibration concrete blocks. It is sufficient to calculate the floor as for static weight loading capacity

Engine room should be ventilated naturally or by ventilators with minimum three times per hour air change rate. Minimal air change quantity technically required corresponds to the heat lost from co-generation unit and inlet air to be burned by engine – see technical parameters chapter. Other safety requirements for air change will be solved according to locally valid safety rules and standards. To avoid freezing problems and because of better starting conditions it is recommended to keep inside temperature in the engine room not lower than 5°C.

piping above the roof with min. distance 3 m from possible source of the fire.

piping is made of stainless steel DIN 1.4301

It is absolutely necessary to keep water flow through customer heating circuit when engine is in operation. Danger of exhaust boiler damage.

Earthing of the object with earth resistance less then 5 Ω must be supplied to the switchboard. Generator will be fix grounded according to standard ČSN 33 2000-4-41 article 413.1.

Specific solution and local requirements is always recommended to consult with the manufacturer of the co-generation unit in advance.

Technical Diagram