1. My name is George Anglin I work for Enercon Engineering

2. Enercon is a Global Leader
Over 40 Years in Business
in more than 100 Countries
Enercon is a Global Leader
in the Power Generation and Controls & Switchgear Industry.
Enercon has more then 37,000 projects and services in over 100 countries, including Antarctica, Hawaii, and the Nigerian Sea.

3. What Does Enercon Do? Customized and Standard Switchgear
Custom Control Panels
In-House Programmed SCADA Systems
Circuit Breakers
Genset Packaging, Enclosures, and Containers
(especially CHP)
Retrofit Solutions
Custom Bases and Trailers
Mobile and Stationary Power Modules
Special Assemblies
Complete In-House Testing Services
Product Support Services
Complete System Design & Manufacturing Capabilities
We Specialize in custom projects Especially CHP as they are typically very custom

4. Who am I George Anglin 6 years US Navy Bradley University BSEE
Electrical Design engineer for Power generation, Steel, and Plastics industries
At Enercon For over 13 years
Electrical Design
Programming PLC’s and Generator controllers
Engineering Manager
Team Lead B

5. Challenges of Integrating Modern CHP systems
-Application
-Specification
-Implementation
-Installation and Startup
-Summary
Summary of topics I am going to speak on

6. Application Simple co-generation (or heat recovery) can be achieved by
utilizing a heat exchanger connected in series with engine.
Make sure that the system can handle the BTU output and that there is enough gas.
Situations Enercon has run into:
Projects without enough Methane
Projects without enough cooling
Projects that could not handle the BTU output
No Process Diagram PID
I will not spend a lot of time on the sizing of systems. Listed is things we have come up against throughout the many projects we have done. The key take away is a good PID outlining the heat loops and if possible the control components. Temp sensors, flow, valves. Ect
You cant control a system that is not sized properly!

7. Application What controller should be used
Engine controller with basic PLC function
For simple systems you can use a low cost engine controller. ComMap, Dief, and Woodward all boast smart controllers for engines. Beware that when they say they have a built in PLC that it does not contain all the functionality or capacity of a PLC. From this you can see the foot print consumed by the relay pan which can be a problem when space is a consideration.
Take into consideration I/O count and communications requirements as this will drive you to the type of controller.

8. Application What controller should be used Small PLC or Large PLC
Determining the I/O count and allow 20% spares (Especially analog)
Communications protocols should be considered at this stage as well
You can use low cost PLC’s Again the I/O count is important. Always allow 20% spares including analog. I have seen many PLC maxed out due to changes and additions at start up. Especially when the system is not working well.

9. Application Communications What information is needed
No Really what is needed
How many devices
If there are many you might want a communications Diagram
Communications protocols should be considered at this stage as well
Communications is the next biggest driver for controller selection.
What information is needed. There is large amounts of data being collected around the world never to be looked at again. What devises are you bringing data in for. Meters, generator, motor control, Gas skid, ect.
Choose a universal protocol and make sure it is robust. Cat 5E copper system talking Modbus or Ethernet I/P

10. Application
This is an example of a customer specified component ignoring communications protocol
Communications
Will all device communicate together
Is the communications selected robust enough
Recommend Modbus TCP
Universally supported
Off the shelf connection Cat 5E
Fast enough for monitoring and control
Make sure the specified devices can communicate. Example of Eaton. From factory not wired correctly, and required additional hardware and three trips to get it working.

11. Application Communications
All devices specified must communicate the specified protocol if possible.
Security should be required if connecting to the plant or internet
Use a VPN device such as a Phoenix contact M-guard
Is the site manned or unmanned?
Remote notification
Autodialer
Text or
(Customer IT)
Clearly define what can be accessed
View only
Remote control
Evaluate all devices based on these requirements
Security
Stuxnet – Story
What will the customer IT allow
Web enabled devices simplifies remote connectivity.

12. Specification Control Systems Wrong system specified
Full blown SCADA for small CHP system
SCADA
Remote Control – Do you need it or want it
Historical - If you have a Emissions panel may not need
Trending – For tuning and balancing the system and loops
Manned site or Unmanned
Local requirements
Sell back
Control System specified to match the CHP project
30K SCADA for a 100K project
Scada _ Supervisory Control and Data Acquisition
Remote control
Sems panel
Historical – data base versus event log
Trending
Manned or unmanned
Local requirements
Sell back

13. Implementation Tying all the components together
Communications all speaking the same language
Control valves match the PID
Layout
Can you access items for repair
Can you access them to verify operation
Are the controls properly protected
What is the foot print you have to fit in.
Implementation
Tiing all the communications together from all vendors
Control components match PID
Tight spaces
Existing sites adding CHP provide footprint challenges

14. Implementation D-3456 package genset equipped with fire-tube
type exhaust heat recovery
silencer, process water
heat exchanger ----
utilizes engine mounted
radiator for thermal load
dump
Hospital application in
Hawaii using the hot water
for laundry and other
processes
On larger engines it is not as much of a challenge

15. Implementation Module in operation during winter months
note vapor from exhaust
Enclosure package sound
attenuated for 75 dba at 1m
and is very quiet
When you have a complete stand alone building for the engine and controls it makes it even better for space considerations. You do need to be aware of the local ambient due to Icing considerations.
When in full heat recovery very little heat going to the radiator. Icing can become an issue. Run fans on high to keep them clear.

16. Implementation 2x G-3516 gas gensets rated 800 KW each plus
450 ton York absorption
chiller
This system is comprised
of 8 interlocking modules
which was site-erected
in 2 days on job
Project was located on
The 8th floor in
New York city
Modular has to be handled differently. This was in 7 pieces. All the controls we wired and pulled back. This was installed on the 8th floor in NY over a weekend.
Watch for code differences NY versus the rest of the uS

17. Installation and Start-up
Factory Testing
Try to connect all devices
Verify communications
Verify controls
Use simulation
Integrated testing preferred
Will not be able to test heat recovery until at site
Factory testing
Strongly recommend that it is done.
Explain next two drawings

18. Installation and Start-up
Factory Testing
Scada Debug
Revenue metering
Skid control station
SCADA panel and Remote HMI as well as metering panel.

19. Installation and Start-up
Factory Testing
Run the engine and verify controls and all sensors, valves, and connections
This is a methane system we ran on Natural gas. Had to be retuned at site.
Reduce on site start up time
There are systems that this can’t be done on.
Complete package skid. Small enough to fully test in our facility connected to our radiator farm. Able to run on natural gas and test many items and debug. Had to retune for Digester gas at site but minimize startup time.

20. Conclusion Questions? Summary
CHP can be done successfully if managed well
Knowing the site requirements and attempting to match customers concerns
Factory testing is worth the added expense if it is possible
Questions?
Summarize all.