Portable Biogas Microturbine Power System Installation
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1 Portable Biogas Microturbine Power System Installation CANMET Energy Technology Centre & The City of Calgary Chuck Smith, P.Eng. CH2M HILL 5th Annual Microturbine Applications Workshop January 25-27, 2005, Ottawa, ON
2 Project Organization Funding & Project Support CETC (75%): Microturbine Trailer Operations The City of Calgary (25%): LFG Recovery, Supply & Monitoring Project Management CH2M HILL
3 Installation Summary Location: Shepard Landfill, Calgary, AB Portable Unit: Trailer-mounted Capstone C30 complete with on-board LFG conditioning system Unit initially tested in 2001 (1,051 hours); Re-installed November 2003 with LFG conditioning system upgrades; Operated to November 2004 (6,202 hours)
4 Installation Summary Grid interconnected installation Trailer sited on top of completed landfill waste cell; 25kV feeder brought to unit CompAir Hydrovane 15 hp compressor used to draw LFG under vacuum from dedicated LFG extraction wells on site LFG flow rate ~ 22 m 3 /h for 30 kw Capstone C30 microturbine
5 Site Installation 25 kv Interconnection Point Microturbine Trailer LFG Extraction Well (TYP) Abovegrade Gas Lines (3 LFG Wells connected)
6 Project Goals Obtain at least 6 months or 4,000 hours of operational experience Unattended operation with Web-based monitoring system Site visits for routine O&M to be on a monthly basis
7 Unit Equipment Summary Gas processing system Inlet filtration - coalescing filter VanAir deliquescent gas dryer low pressure (Model D-30) Comp Air Hydrovane Model GK707 rotary vane 15 hp compressor direct-coupled dual-circuit aerial cooler for gas and lube oil cooling Compressor control panel
8 Unit Equipment Summary High pressure water knock-out vessel Gas/glycol heat exchanger (plate type) for optional gas chilling system Gas/gas heat exchanger (plate type), to re-heat the gas ~ 10 C above dewpoint AFT SAG-18 siloxane filtration system Automated condensate handling system
9 CompAir Hydrovane GK707 Compressor Gas Aftercooler AFT-SAG-18 Siloxane Filter Condensate K.O. Gas/Glycol Heat Exchanger (optional Chilling Loop available)
10 Unit Equipment Summary Power generation system Capstone 30 kw microturbine Unifin Microgen Heat Recovery unit DY600 heat-driven adsorption chiller initially installed and tested for gas chilling application; removed due to limitations of the DY unit capacity and system component failures Electrical room (power output 480V or 600V) Net-Flow Web-based monitoring system
11 Unifin MicroGen HRU Manual Exhaust Diverter Valve Low Voltage Visible/Fused Disconnect Import/Export Meter Capstone C30 DY600 Chiller Trailer Electrical Panel
12 Electrical Single Line Diagram
13 LFG Conditioning System Performance LFG conditioning system operated as designed; only minor maintenance issues Downtime associated with fuel gas system: Condensate dump valve malfunction on air delivery side (two separate occasions) Fuel gas PCV upstream of microturbine not seating properly. Deposits found on valve seat Total Siloxanes measured: Raw LFG from the wellfield: Treated LFG to Microturbine: 5.13 ug/l 0.05 ug/l
14 Electrical Performance Operation Interval April 3 November 13, 2004 Max. Turbine Output (kwe) 30 Min. Turbine Output (kwe) 25 Average Power Output (kwe) 27 Total Estimated Power Generated during interval (kwh) 111,000 Total Microturbine Online Hours 4,425 Total Power Exported to Grid (kwh) 83,067 Total Power Imported from Grid (kwh) 1,278 Average Net Power Output to Grid (kw) 20 Average Parasitic Power (kw) (compressor, pumps, fans, lighting, etc.) 7 Average Onsite Parasitic Power (as a % of total) 25% System Online Availability during interval 84%
15 O&M Performance Availability Nov Nov = 59% Delays in DY600 installation/modifications DPC failure and delays in repair (1,428 hours) Microturbine generator shaft failure (1,527 hours) Availability Apr Nov = 84% Projected annual O&M costs = $28,000 Microturbine and HRU ~ 3.7 cents/kwh Gas Conditioning System ~ 9.0 cents/kwh Above costs based on quarterly inspection for the microturbine and PM on gas compressor
16 Capstone C30 On-line Output April - November Power (KWe) Web-Based Monitoring System Operational Average Power output Fuel Fault ESD Valve (Low N2 Pressure on ESD Valve - FC) DY600 Chiller Testing (May 20 to June 8) Fuel Conditioning System Maintenance Remove DY600 System Offline Compressor Service + Oil Change (4550 hrs) Fuel Pressure Fault To MT Decommission MT Trailer System Nov Planned ENMAX Outage Fast Undervolt Phase C INVDSP Bus Over Voltage Fuel Fault ESD Valve (low N2 Pressure on ESD Valve - FC) Finish Test Phase /05/ /15/ /24/ /03/ /26/ /17/ /09/ /18/ /28/ /07/ /20/ /30/2004 Date
17 Web-Based Monitoring Last Poll: :57:08 CETC MICROTURBINE TRAILER - SHEPARD LANDFILL, CALGARY, AB Process Information Gas Temperatures Phase A Power Average 10 kw Heat Exchange Temperature C Phase B Power Average 9.88 kw Heat Exchange Temperature C Phase C Power Average kw Heat Exchange Temperature C Power Output kw Heat Exchange Temperature C Phase A Current 33.9 A Heat Exchange Temperature 5 0 C Phase B Current A Heat Exchange Temperature 6 0 C Phase C Current A Heat Exchange Temperature 7 0 C Neutral Current 0 A Heat Exchange Temperature 8 0 C Total Phase Current A Other Temperatures Phase A Output Voltage V MicroTurbine Room Temperature 6.31 C Phase B Output Voltage V Compressor Room Temperature 4.94 C Phase C Output Voltage V Outside Ambient Temperature 4.81 C Frequency DY Chiller Parameters Supply Voltage V Energy Flow Rate MJ/hour Ambient Pressure 89 kpa Cooler Temperature C Exhaust Temperature C Energy Flow Rate MJ/hour Engine Speed RPM Cooler Temperature C Exhaust Temperature C Export Power Meter Run Time 5979 Hrs Power Plus 0 kw Microturbine Alarm Status Power Minus 0 kw RPM Alarm Status Power Plus Var 0 kvar CO Alarm Status Power Minus Var 0kVar DY-Chiller Alarm Status - Currently Offline Landfill Gas Parameters Flow Rate 20.5 m3/h Methane 58.5 % Oxygen 0.35 %
18 System Component Failures Major DPC components failure (1,428 hours) IPM Module burn-out Pre-charge board Phase C resistor Inverter IGBT open Microturbine shaft failure (1,527 hours) Minor Gas Compressor - motor coupling failure (4,550 hours)
19 General Experience Areas for Improvement Reduce O&M costs through local mechanical service company and trained local technician Future Market Opportunities Smaller remote landfill sites, or small-scale digester gas operations Development / R&D Opportunities Field testing new micro-power generation systems - e.g. Stirling engines
20 Overall Experience After replacement of microturbine hot-section, the system operated at over 80% on-line availability; down-time associated with grid faults and fuel faults Adjustments in protective relay settings and with fuel delivery system maintenance, on-line availability increased to over 90% High projected O&M costs associated with biogas compression and treatment, resulting from: Lack of local service Oversized capacity for future power generation Web-based system effective for system monitoring and data storage
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