Technical Spec Sheet | BIOGAS CHP Module | Energy Conversion System | 60Hz - 480V - 3Ph

Series

CHP Cogeneration System

With Thermo
Thermo--Dynamics Technology
Digital 2G GEM
General Electronic Management

02/2013

1426 ekW
60Hz

Basic Description

CHP Module | 1426 kW/h 480V - 60Hz - 3Ph

Comprehensive Basic Scope of Supply

Advanced CHP Technologies

Unique Features with Added Value

Reliable, rugged and highly durable factory-designed, production line assembled, professionally
packaged, and post-production tested 2G Biogas Cogeneration Module, supplied in an all-in
-one package that is connection-ready. Manufactured at 2G ISO compliant production facilities in the USA . This CHP (Combined Heat & Power) cogeneration equipment is a fully integrated power generation system, with state-of-the-art technology that results in optimum performance and efficiency. The 2G CHP module integrates all cogeneration components into one
unique package that converts energy more efficiently than conventional CHP systems.
The robust design utilizes full authority electronic engine management, incl. CHP performance
monitoring that provides prolonged life, low maintenance, and high efficiency. Items such as,
engine & system controls, synchronizing and paralleling switchgear, heat recovery (both for
engine jacket water and exhaust), the entire thermal heat technology system, pumps, piping,
plumbing, etc., are all included within the module dramatically reducing the risk of cost overruns and performance issues associated with conventional site built systems.
The 2G CHP module allows for optimized efficiency by maximizing heat recovery and
applying a more efficient combustion technology, leading to a higher electrical output.

Complete CHP Module

Small Footprint incl. Thermo Dynamics Technology

High Efficiency Biogas Engine (Lean Burn Technology)

Advanced and Optimized Exhaust Gas Turbocharger
Electrical Jacket Water Heater System in Cold Regions
Extra Large Oil Capacity Sump with Oil Refill Automatic
Pressure Lubrication System with Gear Pump
Advanced CHP Type Air Cleaner System
Gas Train & Biogas Fuel System compliant with NFPA 37,
tested and approved to UL, CSA, EU, and DIN Standards
Biogas Blower, Explosion-proof tested and ATEX certified
Advanced High Efficiency Two-Stage Fuel Mixer
Proprietary Air/Fuel Ratio Controller
Digital Microprocessor Controlled Electronic Ignition
Heat Value Fluctuation Detection
Vibration Detection & Detonation Protection
Complete Heat Recovery System , Factory installed
Self-Cleaning Jacket Water Plate Heat Exchanger
High Efficiency Stainless Steel Exhaust Heat Exchanger
Exhaust System incl. Flex Connector & Silencer
Ultra Low Emissions Capability
Thermal Heat Distribution Connections fully integrated
Thermo Dynamics Technology
Advanced Cooling System, Mixture Inter-Cooler & Dry
Radiator / Re-Circulation Cooling System (beltless)
General Digital Control System with Protection Devices
Heat Value Fluctuation Detection Technology
Utility Grade Switchgear (CSA, UL, NEMA, IEEE, CE)
Grid Interconnection Relays per CSA/UL & IEEE 1547
Electronically operated Circuit Breaker
Optimized High Efficiency Synchronous Generator
Electrical Load Share Governor System
24V Electrical Starter, Battery Rack & Cables
Integrated High Performance Battery Charger
Central Wiring Harness incl. Sensors
Torsion-resistant Design with Solid Frame Structure
Heavy Duty Oscillation Decoupling Devices
Multiple Deck Design with integrated Spill Tray
Biogas Micro Filtration System
Fluidistor Gas Flowmeter & Gas Vacuum Sensor
Gas Pressure, Gas Temperature, and Ambient Air
Temperature Sensors
Double Magnet Valve & Zero Pressure Regulator
By-Directional Deflagration Flame Arrestor, ATEX Cert.
Set of Pressurization & Expansion Vessels & Valves
Three Way Valve & Electrothermic Actuator
Set of GRUNDFOS VersaFlo self-lubricated Main
Hot Water Circulation Pumps and Sensors
Optional Thermal Distribution Assembly fully integrated
Water Circulation Dirt Collection Unit
On-Line Remote Monitoring & Control

CHP Module | Fully Containerized Option

A genuine Plug & Play Biogas CHP Solution
2G advanced container modules are designed for easy operation, to minimize
floor space, and to contain the entire CHP cogeneration plant in one unit all-inone. Due to a compact layout with integrated control-and switchgear equipment, as
well as a ventilated noise protection enclosure, these modules can be placed anywhere, even in residential areas. A smart and economical alternative to traditional
inside installations; highly efficient and much more cost-effective.

This containerized modular System is guaranteed

less expensive than a traditional Inside Building
Installation

Anaerobic Farm Digester Biogas CHP Power Generation Plant

with Plug & Play Container Module.

Containerized CHP modules provide many advantages. All heat exchanger and
heat recovery systems are fully integrated. Heat circulation piping and distribution
are an integral part of our containerized solutions. Insulated piping, pre-plumbing,
all connection-ready. The floor plan allows for easy access to all system components, comfortable movement, and efficient service & maintenance. 2G modules
are especially built, not just modified shipping containers. Standard connections
and terminations are used throughout to minimize the installation and connection
effort. All units are designed for extreme fast integration and very easy operation.
Installation time is typically 2 days.

Landfill Gas (LFG) Power Generation Plant with Plug & Play
Container Module, including Gas Conditioning & Treatment System.

Your Benefits

Reduced Cost and decreased Project Lead Time

Reliability and Top Performance all
all--in
in--one Factory tested
Less technical Risk & more economical
Optimal Solution with significant Advantages for the Owner
Versatile, flexible, scalable, and unrestrained Mobility

Municipal Dry Anaerobic Digester Biogas CHP Power Generation

Plant with Plug & Play Container Module, including Gas Conditioning & Treatment System.

Multiple Process Control

Total Integration including Paralleling Capability

Advanced CHP Control Technology | Unique Features with Added Value

Standard Equipment included
GEM is equipped with a fully integrated electronic Governor Control (Speed & Load
Sharing, kW / kVAR), and a variety of control modules consisting of:
Actuators
3-Phase Monitoring of Voltage & Current
Load Management
Power Function Regulation
Select Switch for Droop Mode
Controls for Stability & LoadGain

Speed Sensing & Control

Load Sensor
Ramp Generator for Ramp Time and Idle
Digital Generator Control
Voltage Regulator Sensing & Control
Rheostat for Control of Speed for Synchronization

The Generator Protection Unit DEIF GPU-3 is a compact microprocessor-based protection relay containing a wide variety of vital functions for advanced synchronous generator protection.

Multiple Process Control Features for the entire CHP System:

In addition to the basic power generation system & paralleling / synchronization and
load management control functions, GEM also controls space ventilation, combustion
air flow, adjustments based on ambient air & temperature, gas pressure, gas volumes,
gas treatment incl. re-heating, gas & smoke safety devices, flare, communication interface with digester or other customer PLCs, thermal energy & heat extraction management, pumps & hot water circuits, A/C system, space heating, oil replenishing, emissions, catalytic converter, SCR, and much more.
GEM provides total integration including paralleling capability, grid or load-share
mode, precise frequency & voltage regulation, alarm & status message display,
protection, output metering, auto-shutdown, auto-restart, and a comprehensive
user interface. All mounted inside a NEMA type enclosure.
Ammeter
Undervoltage / Overvoltage
Wattmeter
Reverse Power Relay
Loss of Exitation Relay
Overcurrent Relay
Auxiliary CBs, Relays & Timers
Generator Main CB (Circuit Breaker)
electronically operated including
Indicator Lights, installed in its
own protected Enclosure Panel

Voltmeter
Frequency Meter
Power Factor Meter
Directional Power
Reverse VAR Relay
Negative Sequence
CT / PT Functions

Voltage Restraint
Underfrequency / Overfrequency
Digital Governor Control
Synchronization Relay
Phase Balance Relay
Ground Fault Relay

User Interface Protocols

Customers have the option to select Profibus or Modbus configurations. Operators intending to interface with
AB PLCs are required to install the AB FLEX I/O PROFIBUS adapter or similar network interface translators.

Cutting Edge Technology

Fully integrated & Factory tested

Providing more Capability in less Space
Enhanced Protection & greater Flexibility
Comprehensive Functions for Diagnostics

All Functions per CAS/UL &

IEEE 1547 Requirements

0.01 Technical Data (at module)

Data at:
Fuel gas LHV

kWh/Nm

Energy input
Gas volume
Mechanical output
Electrical output
Recoverable thermal output
~ Intercooler 1st stage
~ Lube oil
~ Jacket water
~ Exhaust gas cooled to 180 C
Total recoverable thermal output
Total output generated
Heat to be dissipated
~ Intercooler 2nd stage
~ Lube oil
~ Surface heat
~ Balance heat
Spec. fuel consumption of engine
Lube oil consumption
Electrical efficiency
Thermal efficiency
Total efficiency
Hot water circuit:
Forward temperature
Return temperature
Hot water flow rate

Full
Part Load
load
4,5
100%
75%
50%

kW

[2]

Nm/h

*)

kW

[1]

kW el.

[4]

kW
kW
kW
kW
kW

[5]

kW total

kW
kW
ca.

kW

[7]

kW

ca.

kWh/kWh

[2]

kg/h

[3]

%
%
%

C
C
m/h

[6]

3.538
786
1.466
1.426

2.743
610
1.100
1.068

1.948
433
733
706

215
164
400
737
1.516
2.942

60
151
384
616
1.211
2.279

15
113
294
471
893
1.599

69
~
118
35

45
~
111
27

26
~
111
19

2,41
0,44
40,3%
42,8%
83,2%

2,49
~
38,9%
44,1%
83,1%

2,66
~
36,2%
45,8%
82,1%

95,0
75,0
72,5

89,4
75,0
72,5

85,6
75,0
72,5

*) approximate value for pipework dimensioning

[_] Explanations: see 0.10 - Technical parameters
All heat data is based on standard conditions according to attachment 0.10. Deviations from the standard conditions can result in a
change of values within the heat balance, and must be taken into consideration in the layout of the cooling circuit/equipment
(intercooler; emergency cooling; ...). In the specifications in addition to the general tolerance of +/- 8% on the thermal output a
further reserve of 10% is recommended for the dimensioning of the cooling requirements.

Main dimensions and weights (at module)

Length
Width
Height
Weight empty
Weight filled

mm
mm
mm
kg
kg

~ 7.100
~ 1.800
~ 2.200
~ 15.000
~ 15.700

Connections
Hot water inlet and outlet
Exhaust gas outlet
Fuel gas (at gas train)
Fuel Gas (at module)
Water drain ISO 228
Condensate drain
Safety valve - jacket water ISO 228
Safety valve - hot water
Lube oil replenishing (pipe)
Lube oil drain (pipe)
Jacket water - filling (flex pipe)
Intercooler water-Inlet/Outlet 1st stage
Intercooler water-Inlet/Outlet 2nd stage

DN/PN
DN/PN
DN/PN
DN/PN
G
DN/PN
DN/PN
DN/PN
mm
mm
mm
DN/PN
DN/PN

100/10
300/10
125/16
125/10
''
50/10
2x1''/2,5
65/16
28
28
13
100/10
65/10

Output / fuel consumption

ISO standard fuel stop power ICFN
Mean effe. press. at stand. power and nom. speed
Fuel gas type
Based on methane number|Min. methane number
Compression ratio
Min./Max. fuel gas pressure at inlet to gas train
Allowed Fluctuation of fuel gas pressure
Max. rate of gas pressure fluctuation
Maximum Intercooler 2nd stage inlet water temperature
Spec. fuel consumption of engine
Specific lube oil consumption
Max. Oil temperature
Jacket-water temperature max.
Filling capacity lube oil (refill)
c) Lower gas pressures upon inquiry
d) based on methane number calculation software AVL 3.1

kW
bar
MZ d)
Epsilon
mbar
%
mbar/sec
C
kWh/kWh
g/kWh
C
C
lit

1.466
16,00
Biogas
135|100
12,50
120 - 200 c)
10
10
55
2,41
0,30
85
95
~ 437

0.02 Technical data of engine

Manufacturer
Engine type
Working principle
Configuration
No. of cylinders
Bore
Stroke
Piston displacement
Nominal speed
Mean piston speed
Length
Width
Height
Weight dry
Weight filled
Moment of inertia
Direction of rotation (from flywheel view)
Flywheel connection
Radio interference level to VDE 0875
Starter motor output
Starter motor voltage

mm
mm
lit
rpm
m/s
mm
mm
mm
kg
kg
kgm

kW
V

GE Jenbacher
J 420 GS-B81
4-Stroke
V 70
20
145
185
61,10
1.800
11,10
3.750
1.580
2.033
6.600
7.300
11,64
left
SAE 18''
N
13
24

Thermal energy balance

Energy input
Intercooler
Lube oil
Jacket water
Exhaust gas total
Exhaust gas cooled to 180 C
Exhaust gas cooled to 100 C
Surface heat
Balance heat

kW
kW
kW
kW
kW
kW
kW
kW
kW

3.538
284
164
400
1.110
737
931
78
35

Exhaust gas data

Exhaust gas temperature at full load
Exhaust gas mass flow rate, wet
Exhaust gas mass flow rate, dry
Exhaust gas volume, wet
Exhaust gas volume, dry
Max.admissible exhaust back pressure after engine

[8]

kg/h
kg/h
Nm/h
Nm/h
mbar

470
8.098
7.526
6.295
5.609
60

Combustion air data

Combustion air mass flow rate
Combustion air volume
Max. admissible pressure drop in front of intake-air filter

kg/h
Nm/h
mbar

7.466
5.775
10

Sound pressure level

Aggregate b)
31,5
Hz
63
Hz
125
Hz
250
Hz
500
Hz
1000
Hz
2000
Hz
4000
Hz
8000
Hz
Exhaust gas a)
31,5
Hz
63
Hz
125
Hz
250
Hz
500
Hz
1000
Hz
2000
Hz
4000
Hz
8000
Hz

dB(A) re 20Pa
dB
dB
dB
dB
dB
dB
dB
dB
dB
dB(A) re 20Pa
dB
dB
dB
dB
dB
dB
dB
dB
dB

97
79
87
98
95
91
86
88
92
89
115
95
117
115
113
108
105
108
109
107

Sound power level

Aggregate
Measurement surface
Exhaust gas
Measurement surface

dB(A) re 1pW
m
dB(A) re 1pW
m

117
107
123
6,28

a) average sound pressure level on measurement surface in a distance of 1m according to DIN 45635, precision class 2.
b) average sound pressure level on measurement surface in a distance of 1m (converted to free field) according to DIN 45635,
precision class 3.
The spectra are valid for aggregates up to bmpe=19 bar. (add savety margin of 1dB to all values per increase of 1 bar pressure).
Operation with 1200 rpm see upper values, operation with 1800 rpm add 3 dB to upper values.
Engine tolerance 3 dB

0.03 Technical data of generator

Manufacturer
Type
Type rating
Driving power
Ratings at p.f. = 1,0
Ratings at p.f. = 0,8
Rated output at p.f. = 0,8
Rated current at p.f. = 0,8
Frequency
Voltage
Speed
Permissible overspeed
Power factor lagging
Efficiency at p.f. = 1,0
Efficiency at p.f. = 0,8
Moment of inertia
Mass
Radio interference level to VDE 0875
Construction
Protection Class
Insulation class
Temperature (rise at driving power)
Maximum ambient temperature
Total harmonic distortion

kVA
kW
kW
kW
kVA
A
Hz
V
rpm
rpm
%
%
kgm
kg

C
%

LEROYS or STAMF e)
PE 734 E2 e)
2.140
1.466
1.426
1.416
1.770
2.129
60
480
1.800
2.160
0,8 - 1,0
97,3%
96,6%
44,49
3.506
N
B3/B14
IP 23
H
F
40
1,5

Reactance and time constants

xd direct axis synchronous reactance
xd' direct axis transient reactance
xd'' direct axis sub transient reactance
Td'' sub transient reactance time constant
Ta Time constant direct-current
Tdo' open circuit field time constant

p.u.
p.u.
p.u.
ms
ms
s

2,47
0,15
0,11
20
20
2,46

e) GE Jenbacher reserves the right to change the generator supplier and the generator type. The contractual data of the
generator may thereby change slightly. The contractual produced electrical power will not change.

0.04 Technical data of heat recovery

General data - Hot water circuit
Total recoverable thermal output
Return temperature
Forward temperature
Hot water flow rate
Nominal pressure of hot water
Pressure drop hot water circuit
Maximum Variation in return temperature
Max. rate of return temperature fluctuation

kW
C
C
m/h
bar
bar
C
C/min

1.516
75,0
95,0
72,5
10
0,90
+0/-20
10

Mixture Intercooler (1st stage)

Type
Nominal pressure of hot water
Pressure drop hot water circuit
Hot water connection

bar
bar
DN/PN

gilled pipes
10
0,30
100/10

Mixture Intercooler (2nd stage) (Intercooler separate)

Type
Nominal pressure of hot water
Pressure drop hot water circuit
Hot water connection

bar
bar
DN/PN

gilled pipes
10
0,80
65/10

Heat exchanger lube oil

Type
Nominal pressure of hot water
Pressure drop hot water circuit
Hot water connection

plate heat exchanger

10
0,20
bar
100/10
DN/PN
bar

Heat exchanger engine jacket water

Type
Nominal pressure of hot water
Pressure drop hot water circuit
Hot water connection

plate heat exchanger

10
bar
0,20
bar
100/10
DN/PN

Exhaust gas heat exchanger

Type
PRIMARY:
Exhaust gas pressure drop approx
Exhaust gas connection
SECONDARY:
Nominal pressure of hot water
Pressure drop hot water circuit
Hot water connection

shell-and-tube

bar
DN/PN

bar
bar
DN/PN

0,02
300/10

6
0,20
100/10

0.05 Technical parameters

All data in the technical specification are based on engine full load (unless stated otherwise) at specified
temperatures and the methane number and subject to technical development and modifications.
All pressure indications are to be measured and read with pressure gauges (psi.g.).
(1) At nominal speed and standard reference conditions ICFN according to DIN-ISO 3046 and DIN 6271,
respectively
(2) According to DIN-ISO 3046 and DIN 6271, respectively, with a tolerance of + 5 %.
Efficiency performance is based on a new unit (immediately upon commissioning).Effects of
degradation during normal operation can be mitigated through regular service and maintenance work;
(3) Average value between oil change intervals according to maintenance schedule, without oil change
amount
(4) At p. f. = 1.0 according to VDE 0530 REM / IEC 34.1 with relative tolerances
(5) Total output with a tolerance of +/- 8 %
(6) According to above parameters (1) through (5)
(7) Only valid for engine and generator; module and peripheral equipment not considered
(8) Exhaust temperature with a tolerance of +/- 8 %
Radio interference level
The ignition system of the gas engines complies the radio interference levels of CISPR 12 and EN 55011
class B, (30-75 MHz, 75-400 MHz, 400-1000 MHz) and (30-230 MHz, 230-1000 MHz), respectively.
Definition of output
ISO-ICFN continuous rated power:
Net break power that the engine manufacturer declares an engine is capable of delivering continuously,
at stated speed, between the normal maintenance intervals and overhauls as required by the
manufacturer. Power determined under the operating conditions of the manufacturers test bench and
adjusted to the standard reference conditions.
Standard reference conditions:
Barometric pressure:
1000 mbar (14.5 psi) or 100 m (328 ft) above sea level
Air temperature:
25C (77F) or 298 K
Relative humidity:
30 %
Volume values at standard conditions (fuel gas, combustion air, exhaust gas)
Pressure:
1013 mbar (14.7 psi)
Temperature:
0C (32F) or 273 K
Output adjustment for turbo charged engines
Standard rating of the engines is for an installation at an altitude 500 m and an air intake temperature
30 C.
If the actual methane number is lower than the specified, the knock control responds. First the ignition
timing is changed at full rated power. Secondly the rated power is reduced. These functions are carried
out by the engine management system.

CHP Cogeneration Energy Conversion Systems

Low Emissions & BACT (Best Available Control
Technology) Ultra-Low Emissions Capable
All 2G CHP systems and engines include BACT (Best Available Emissions Control Technology), are in compliance with Federal EPA Rules &
Regulations and carrying the voluntary Manufacturers EPA Emissions Certificate of Compliance in accordance with EPA Subpart JJJJ of Part 60
(Digester Gas, Biogas, LFG, Natural Gas) lean burn Gas Engine (IC Internal Combustion) - 73 FR 3591. All specified emission values < less than /
without after treatment. For lower values an Oxidation Catalyst can be installed (optional). For CARB and South California AQMD, emissions can
be drastically reduced with 2Gs SCR Exhaust Gas Treatment Module).
Please contact us if you have to comply with specific local regulations and
site-specific limitations.
All Data according to full load and subject to technical development, modification and change. Exhaust gas emissions correspond to dry exhaust gas
and 10% residual Oxygen O2. Lean burn and BACT technology and provide exhaust emissions well below EPA Federal Guidelines & Regulations.
Additional emissions treatment and reduction technologies (Oxi-Cat, SCR,
De-Nox, etc.) are available as an option if required.

2G CHP Systems are designed, and manufactured in Accordance

with all applicable Standards.

Electrical output based on ISO standard and conditions according to ISO

3046/1, VDE 0530, and to SAE J1349 with respective tolerance. Technical
data is based on a gas quality 55% CH4 and carbon dioxide CO2 <45% and
a heat value of >5 kWh/Nm. For conditions or fuels other than standard,
consult 2G-CENERGY.
Tolerances: electrical output ISO 3046/1, fuel consumption +/- 5%, thermal
output +/- 8%. Typical heat data is shown, however no guarantee is expressed or implied. Data will vary due to variations in site and ambient conditions.
All electrical systems comply with DIN, VDE, CE, and CSA certifications,
and NEMA / UL compliant designs / configurations. The generator is compliant with international standards & regulations IEC 60034, NEMA MG
1.22, ISO 8528/3, CSA, UL 1446, UL 1004B, DIN 6280-3, VDE 0530, VEM 10, ISO 8528-3, BS 5000, IEC 34, designed and manufactured in an ISO
9001 and ISO 14001 environment.
Gas treatment might be necessary (depending on the actual gas quality).
Applicable gas types: Low BTU (weak gases), e.g. Biogas, Landfill Gas,
Sewage Gas, Coal Mine Gas. Other specialty gases upon request (High
BTU Wellhead Gas, Wood Gas, Syngas, Coke Gas, Pyrolysis Gas).
The Manufacturer reserves the Right to change or modify technical Details
without prior Notice.

Proven Technology incl. Performance Guarantee

Modular, All
All--In
In--One, Fully integrated & Factory tested
Plug & Play, more Cost
Cost--effective, more economical
Versatile, flexible, scalable, and unrestrained Mobility
Reliable, proven, with unmatched Quality & Performance

2G CENERGY Power Systems Technologies Inc.

205 Commercial Drive
St. Augustine, FL 32092 - USA
Tel.: +1-904-579-3217
Fax: +1-904-406-8727
Email: info@2g-cenergy.com
Website: http://www.2g-cenergy.com