Final
                               July, 2008


                      SRI/USEPA-GHG-QAP-45
                               July, 2008
    Test and Quality Assurance
    Plan
    Building Energy Solutions, LLP
    Tecogen DG / CHP Installation
SOUTHERN RESEARCH
mdi'ir Dlico¥ifl*i- iM-fUnf Innamli
                       Prepared by:
 Greenhouse Gas Technology Center

          Operated by
    Southern Research Institute
 &EPA
  IW5ERDA
   Under a Cooperative Agreement With
U.S. Environmental Protection Agency

             and

       Under Agreement With
  New York State Energy Research
    and Development Authority

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Final                                                                                          My, 2008
                                        EPA REVIEW NOTICE

 This report has been peer and administratively reviewed by the U.S. Environmental Protection Agency, and
 approved for publication. Mention of trade names or commercial products does not constitute endorsement or
 recommendation for use.

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  Final
                            July, 2008
         Greenhouse Gas Technology Center
        A U.S. EPA Sponsored Environmental Technology Verification ( ETr ) Organization
                     Test and Quality Assurance Plan
                         Building Energy Solutions, LLP
                         Tecogen DG / CHP Installation
This  Test and Quality  Assurance  Plan has been  reviewed  and  approved by the Greenhouse Gas
Technology Center Project Manager and Center Director, the U.S. EPA APPCD Project Officer, and the
U.S. EPA APPCD Quality Assurance Manager.
Tim A. Hansen       24 July 2008
Director
Greenhouse Gas Technology Center
Southern Research Institute
Lee Beck            15 July 2008
APPCD Project Officer
U.S. EPA
William Chatterton    24 July 2008
Project Manager
Greenhouse Gas Technology Center
Southern Research Institute
Robert Wright        16 July 2008
APPCD Quality Assurance Manager
U.S. EPA
EricRingler          21 July 2008
Quality Assurance Manager
Greenhouse Gas Technology Center
Southern Research Institute

Test Plan Final: 10 July 2008

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                                         [Blank Page]

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                               TABLE OF CONTENTS
                                                                                 Page
LIST OF FIGURES	i
LIST OF TABLES	i
ACRONYMS AND ABBREVIATIONS	ii

1.0   INTRODUCTION	1-1
     1.1.  PURPOSE	1-2
     1.2.  PARTICIPANTS, ROLES, AND RESPONSIBILITIES	1-2
     1.3.  TEST SCHEDULE	1-4

2.0   TEST PROCEDURES	2-1
     2.1.  TEST CONCEPTS AND OBJECTIVES	2-1
          2.1.1.  Controlled Test Period	2-1
          2.1.2.  Long-term Monitoring Period	2-2
          2.1.3.  Instrument Specifications	2-4
     2.2.  SITE-SPECIFIC CONSIDERATIONS	2-6

3.0   DATA QUALITY	3-1
     3.1.  DATA ACQUISITION	3-1
     3.2.  DATA QUALITY OBJECTIVES	3-1
     3.3.  DATA REVIEW, VALIDATION, AND VERIFICATION	3-2
     3.4.  INSPECTION AND ACCEPTANCE OF SUPPLIES, CONSUMABLES, AND
          SERVICES	3-3
     3.5.  CALIBRATIONS AND PERFORMANCE CHECKS	3-3
     3.6.  AUDITS OF DATA QUALITY	3-4
     3.7.  INDEPENDENT REVIEW	3-4

4.0   ANALYSIS AND REPORTS	4-1
     4.1.  ELECTRICAL PERFORMANCE	4-1
     4.2.  ELECTRICAL EFFICIENCY	4-2
     4.3.  CHP THERMAL PERFORMANCE	4-2
     4.4.  ATMOSPHERIC EMISSIONS	4-2

5.0   REFERENCES	5-1

                                LIST OF FIGURES
                                                                                Page
Figure 1-1        Test Participants	1-2
Figure 1-2        Test Schedule	1-4
Figure 2-1        Controlled Test Instrument Locations	2-2
Figure 2-2        Long-Term Monitoring Instrument Locations	2-3

                                 LIST OF TABLES
                                                                                Page
Table 2-1         Instrument and Analysis Accuracy Specifications	2-4
Table 2-2         Instrument Descriptions and Locations	2-5
Table 3-1         Recommended Calibrations and Performance Checks	3-3

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                            ACRONYMS AND ABBREVIATIONS
A             ampere                             mmBtu/h
APPCD       Air Pollution Prevention and
              Control Division                    MQO
BBS          Building Energy Solutions, LLC       MTG
BOCES       Board of Cooperative Educa-          NDIR  '
              tional Services                      NDUV
Btu/h         British thermal units per hour          NMHC
Btu/scf       British thermal units per              NIST
              standard cubic foot
CHP          combined heat and power             NOX
CLD          chemiluminescensce detector          NYSERDA
CO2          carbon dioxide
CO           carbon monoxide
CT           current transformer                  O2
DG           distributed generation                PEMS
DG / CHP     distributed generation /
              combined heat and power             ppmv
DHW         domestic hot water                  QA / QC
DQO         data quality objective
EPA          U. S. Environmental Protection        RTD
              Agency                             scfh
ETV          Environmental Technology            THC
              Verification                         THD
FID          flame ionization detector             Tr
GHG         greenhouse gas                      Ts
gpm          gallons per minute                   V
HRLHV        heat rate, LHV basis, Btu/kWh
Hz           Hertz
1C            internal combustion                  °F
kW           kilowatt                            " H2O
LHV          lower heating value                  TI

                                   DISTRIBUTION LIST
million British thermal units per
hour
measurement quality objective
microturbine generator
non-dispersive infrared
non-dispersive ultraviolet
non-methane hydrocarbons
National Institutes of Standards
and Technology
nitrogen oxides
New York State Energy
Research and Development
Authority
oxygen
portable emissions measurement
system
volume parts per million
quality assurance / quality
control
resistance temperature device
standard cubic feet per hour
total hydrocarbons
total harmonic distortion
return temperature
supply temperature
volt
degrees Fahrenheit
inches of water column
efficiency, percent
New York State Energy Research and Development Authority
       Jim Foster

Building Energy Solutions, LLC
       Rae H. Butler
U.S. EPA Office of Research and Development
       Lee Beck
       Robert Wright

Southern Research Institute (GHG Center)
       Tim Hansen
       William Chatterton
       Eric Ringler

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   Final                                                                             My, 2008
                                   1.0  INTRODUCTION

The intent of this Test and Quality Assurance Plan (test plan)  is to guide the planning, execution, data
analysis, and reporting for performance verification of a Tecogen reciprocating internal combustion (1C)
engine distributed electrical generation and combined heat and  power (DG / CHP) installation designed
and commissioned by Building Energy Solutions, LLP.

Building Energy Solutions (BES) has installed six natural gas-fired Tecogen Model CM-100 Premium
Power CHP modules  as part of a  DG / CHP upgrade at the Madison-Oneida Board of Cooperative
Educational  Services  (BOCES)  campus  located in Verona,  NY.  Appendix B provides CHP module
specifications.

The CHP array will operate in response to electrical demand;  power will not be exported to the grid.
Control of the host facility's peak demand, as seen by the grid,  is a fundamental economic driver for the
system. Operators will adjust each module between 40 and 100 percent power, with 110 percent peaking
power available for short periods.   Operators will be able to dispatch all six units for power demands
between 660 kilowatts (kW) (at peak power) and 264 kW. They will take CHP modules offline for lower
power demands, down to a minimum of 40 kW with one module in operation.

The installation will recover substantial amounts of thermal energy from the 1C engine jacket coolant, oil
cooler, and exhaust. Design specifications indicate that the recovered energy will supply up to 4.4 million
British thermal units per hour (mmBtu/h) to the following district heating and cooling applications:
        •   year-round domestic hot water (DHW)
        •   heat  supply  to two  100-ton absorption chillers  for  air-conditioning  during  warm
           weather
        •   hydronic space heating during cold weather

The facility  also  incorporates two  7500-gallon insulated thermal storage tanks.   Their  function is to
provide approximately 2.5 mmBtu carry-through capacity for space heating and DHW needs during cold
weather periods when electrical demand is low.

The CHP heating and cooling applications will displace fuel consumption at five existing natural gas-fired
boilers rated at 1.94 mmBtu/h each.  Two of the boilers are located adjacent to the CHP installation while
the remaining three are located elsewhere on the campus. Hydronic heating, DHW, and chilled water
piping is generally located in the  ceiling spaces and corridors which connect the various building sections.
The electrical generators, panel boards, circulation pumps, and most other parasitic loads are connected to
the main service bus located in the building "Section H" mechanical room.

The test campaign  will determine the  emissions performance,  electrical performance,  and electrical
efficiency of one CHP module during a "controlled test period".

Assessment of how the overall BOCES facility uses the CHP heat would likely require at least one year
of monitoring, which is beyond this  project's current scope.   This  is because the system permits
dispatching of the CHP heat to five types of loads:
        •   domestic hot water (year round)
        •   two 100-ton chillers (summer)
        •   hydronic space heating (winter)
        •   thermal storage (primarily winter)
        •   heat rejection (any time  CHP heat production exceeds demand or thermal storage)
                                              1-1

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                                 July, 2008
This test campaign will determine the CHP heat production as it leaves the  6-unit Tecogen  system
boundary without quantifying its ultimate use. A one-month "long-term monitoring period" will quantify
the power production, CHP  thermal energy (heat) production, electrical efficiency, thermal efficiency,
and total efficiency of the as-dispatched system.  The project may be modified to incorporate monitoring
of heat and power production and use for a full calendar year should additional funding be secured to do
so.

1.1.  PURPOSE

The  New  York  State  Energy Research and  Development Authority  (NYSERDA)  and  the  U.S.
Environmental Protection Agency (EPA)  Environmental Technology Verification (ETV) program  have
commissioned this test campaign.  Test results also are of interest to the ETV program because previous
CHP verifications have not included either the Tecogen Model CM-100 Premium Power CHP modules or
multi-IC engine arrays.  Also,  few integrated chiller, hydronic heating, and DHW  applications such as
those served by this installation have been tested previously.

1.2.  PARTICIPANTS, ROLES, AND RESPONSIBILITIES

Southern Research Institute's (Southern's) Greenhouse Gas (GHG) Technology  Center will manage the
test campaign. Responsibilities include:
        •   test strategy development and documentation
        •   coordination and execution of all field testing, including:
             o installation, operation, and removal of emissions testing equipment
             o providing  electrical  power monitoring,  CHP  heat  production,  and  data  logging
              equipment
             o subcontract management for installation and removal of electrical power monitors
        •   inspection of calibrations, performance of crosschecks, and other activities
        •   data validation, quality assurance and quality control (QA / QC), and reporting

The Madison-Oneida BOCES building complex located at 4937 Spring Road in Verona, NY will serve as
the host facility.  Southern will work closely with BES personnel to ensure reasonable access to the host
facility and minimal effects on the facility's normal operations.

Figure 1-1 lists test participants and their titles.
          Robert Wright
         US EPA APPCD
           QA Manager


Lee Beck
ITS; FPA Apprri
Project Officer
    Tim Hansen
GHG Center Director
                                                     Bill Chatterton
                                                      GHG Center
                                                    Project Manager
                          Rae Butler
                  Building Energy Solutions, LLP
                           Principal


Bob Richards
GHG Center
Field Team Leader
                            Burl McEndree
                          Empact Analytical
                          Fuel Gas Analyses
                                  Figure 1-1. Test Participants
                                              1-2

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   Final                                                                               My, 2008
Tim Hansen is the GHG Technology Center Director. He will:
        •   ensure the resources are available to complete this verification
        •   review the test plan and verification report to ensure they conform to ETV principles
        •   oversee GHG  Technology  Center staff and  provide  management  support  where
           needed
        •   sign the verification  statement,  along  with the  EPA Office  of Research  and
           Development laboratory director.

Bill Chatterton will  serve as the Project Manager for the GHG Center. He will have authority to suspend
testing  in response to health or safety issues  or  if data quality indicator goals are not met.  His
responsibilities also include:
        •   drafting the test plan and verification report
        •   overseeing the field team leader's data collection activities
        •   ensuring that data quality objectives (DQO) are met prior to completion of testing
        •   maintaining effective communications between all test participants

Bob Richards will serve as the Field Team Leader. He will:
        •   provide field support for activities related to all measurements and data collected
        •   install and operate the measurement instruments
        •   collect gas samples and coordinate  sample analysis with the laboratory
        •   ensure that QA / QC procedures outlined in this test plan are followed
        •   submit all results to the Project Manager to facilitate his determination that DQOs are
           met

The GHG Technology Center QA Manager,  Eric Ringler, is administratively independent from the GHG
Center Director and the field testing staff. Mr. Ringler will:
        •   ensure  that all verification tests are  performed  in  compliance  with  the  QA
           requirements of the GHG  Center quality management plan, the generic protocol [1],
           and this test plan
        •   review the verification test results and ensure that applicable internal assessments are
           conducted as described in the test plan
        •   reconcile the DQOs at the  conclusion of testing
        •   conduct or supervise an audit of data quality
        •   review and validate subcontractor-generated data
        •   report all internal reviews, DQO reconciliation, the audit of data quality, and any
           corrective action results directly to the GHG Center Director,  who  will provide
           copies to the project manager for corrective action  as applicable and citation in the
           final verification report
        •   review and approve the final verification report and statement

Fuel gas analyses will be conducted by Empact Analytical of Brighton,  Colorado under the management
of Burl McEndree.

EPA Office of Research and Development will provide oversight and QA  support for this  verification.
The Air Pollution Prevention and Control Division (APPCD) Project Officer, Lee Beck, is responsible for
obtaining final approval of the Test Plan and Report.  The APPCD QA Manager will review this test plan
and the final Report to ensure they meet the GHG  Center Quality Management Plan requirements and
represent sound scientific practices.
                                               1-3

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                                                       July, 2008
Rae Butler is the principal of BBS, which  is located  at 4133 Griffin Road, Syracuse, NY.  She is
responsible for the DG / CHP system design and will serve as the primary contact for the host facility.
She will also work with the Southern field team leader to  coordinate test activities.
1.3. TEST SCHEDULE


The host facility's electrical design normally requires that the six CHP modules follow the electrical load
as it varies throughout the day.  The controlled test periods, however, will require operations at only one
module.  Dispatchers will shut down the  other five  CHP modules during the  controlled test period.
Normal  dispatching will resume as soon as this test period is finished.  All long-term monitoring will
occur under normal operating conditions.

Southern will install electric power production and parasitic electric load monitoring equipment for use
during the controlled test period. Installers will de-energize the electrical feed briefly during installation
and removal.   Southern  will temporarily install heat transfer fluid flow and temperature monitoring
equipment for use during the long-term monitoring periods.

Figure 1-2 shows the intended test schedule.  Building Energy Solutions and Southern will specify the test
dates upon completion of the installation and commissioning process.
                 Day1
         Test Schedule
             Day 2
            Day 3
  Arrive at site
  Conduct orientation, safety, and other
   conferences
  Unpack Southern's test equipment,
   mobilize, and perform preliminary setups
  Hoist portable emissions monitoring sys-
   tem (PEMS), umbilical, calibration gases,
   and accessory equipment to roof level
  Prepare and install electric power produc-
   tion and parasitic load monitoring equip-
   ment
  Install CHP heat transfer fluid flow and
   temperature monitoring equipment
Complete the monitoring equipment
installations
Withdraw 5 Tecogen modules from normal
 dispatching and shut them down
Start selected module, load it at 100 %
 of capacity, and equilibrate for at least
 10 minutes
Perform 3 controlled test runs, at least %
 hour each at 100 % of capacity
Adjust loading to 75 % of capacity and
 equilibrate for at least 10  minutes
Perform 3 controlled test runs
Adjust loading to 50 % of capacity and
 equilibrate for at least 10  minutes
Perform 3 controlled test runs
Return all Tecogen modules to operation
 and restore normal dispatching
                 Day 4
   Reconfigure test equipment for long-term
    monitoring period
   Begin 1-month long term monitoring period
   Remove and demobilize PEMS and other
    unneeded test equipment
   Pack for shipping and closeout
                                      Figure 1-2. Test Schedule
                                                   1-4

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   Final                                                                             My, 2008
                                 2.0  TEST PROCEDURES

The ETV program has published the Distributed Generation and Combined Heat and Power Field Testing
Protocol [1]  (generic protocol).   The generic protocol  contains detailed test procedures, instrument
specifications, analytical methods, and QA / QC procedures.  This test campaign will generally conform
to the generic  protocol specifications, with modifications  or  special considerations as listed in the
following subsections. Appendix A provides field data forms as derived from the generic protocol.
2.1.  TEST CONCEPTS AND OBJECTIVES

The test campaign will proceed in two phases:
       •   controlled test period
       •   one-month long-term monitoring period


2.1.1.   Controlled Test Period

Southern test  personnel  will be on-site  during  the  controlled  test period to  perform the following
determinations on the selected Tecogen CHP module:
       •   electrical performance (see generic protocol §2.0 for parameters and specifications;
           Appendix Dl for definitions and equations)
       •   electrical efficiency (see generic protocol §3.0 for  parameters  and specifications;
           Appendix D2 for definitions and equations)
       •   gaseous carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOX) and
           total hydrocarbons (THC) emissions performance (see generic protocol §5.0)

The  generic protocol recommends testing at 100, 75, 50, and 25 percent of capacity, but Tecogen
specifies a minimum 40 percent operating  level.   Power levels during the controlled  test  period will
therefore be 100, 75, and 50 percent of capacity.  The generic protocol recommends 1-hour test runs for
internal combustion engines and 30-minute test runs for microturbines.  Southern has found that 30-
minute test runs provide stable data with narrow confidence intervals for both types of power plants. The
controlled test period will therefore  consist of three (3) test runs, each 30 minutes  long, at each power
level. A 10-minute warmup and equilibration period will precede each test run.

Southern will  coordinate the  temporary installation of independent electrical power analyzers  on the
selected module's output bus. Figure 2-1 shows the instrument locations for the controlled  test period.
The  analyzers  will record the electrical performance  parameters at 1-minute intervals or shorter.  The
configuration of the host facility electrical buses will require that the heat rejection air handling unit, heat
rejection pumps, and the CHP circulation pumps to and from the hydronic and DHW heat exchangers be
disconnected as shown in Figure 2-1 during the controlled test periods.  These instruments will allow
proper quantification of the generator and electronics cooling parasitic loads.

Southern will determine gaseous emissions  as CO, CO2, NOX, and THC concentrations with a Horiba
OBS-2200 portable emissions monitoring system  (PEMS). The PEMS also measures exhaust gas flow
with a stack flow tube.  Test personnel will  temporarily install the  PEMS and flow  tube on the selected
unit's exhaust stack. The mean concentration for each  gas during each individual  test run, integrated with
                                              2-1

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                                                             July, 2008
 the mean exhaust gas  volumetric flow rate observed during that test run, will yield the run's gaseous
 emission rate in pounds per hour. Reported results will consist of the mean of three valid test runs.
Tecogen CM-100
Premium Power
CHP Module
                                                               CHP hot water lines
                                                               to / from chiller, hydronic, DHW
                                                               heat exchangers and thermal storage
                                                     Chiller CHP water circulation
                                                     and standby pumps
                                           Emissions performance:
                                           Horiba OBS-2200
                                           portable emissions
                                           monitoring system (PEMS)
CO, CO2,
NOx, THC, O2
H2O, Pamb
                                                   Generator and electronics coolers
                        !  Qfuel, Btu/scf    Vfuel, scfm
                                                                                          DHW heat exchangers
                                                                                          and thermal storage water
                                                                                          circulation and standby pumps
                    LJ4=2,
Heat rejection
air handling unit

   Heat rejection
   and standby
   pumps    ,-
                                                                               kW
                                                                                          LQ-i
                                                                   Electrical lines
                                                                   Building water or
                                                                  ' heat transfer fluid lines

                                                                   Natural gas lines

                                                                   Electrical panel ID


                                                                   Test instrumentation
                           Figure 2-1. Controlled Test Instrument Locations
 Southern will log natural gas consumption data directly from the utility revenue  meter located in the
 Section H mechanical room.  Appendix A-5 provides a field form.  Test personnel will also collect natural
 gas samples for lower heating value (LHV) analysis.
 2.1.2.    Long-term Monitoring Period


 The long-term monitoring period will provide assessments of the following:
         •   electric power production, net
         •   electrical efficiency
         •   CHP   thermal  performance  (see  generic  protocol   §4.0  for  parameters   and
             specifications, Appendix D3 for definitions and equations)
         •   CHP  and total  efficiency  (see generic protocol Appendix D3 for definitions  and
             equations)
                                                   2-2

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                                                                July, 2008
     Southern will  coordinate the temporary installation of three independent electrical power monitors as
     shown in Figure 2-2. The monitors will log the CHP array total generated power and parasitic loads at 1-
     minute intervals or shorter throughout the long-term monitoring period.
                                                 CHP hot water lines
SixTecogen CM-100
Premium Power
CHP Modules
                                      Chiller CHP water circulation
                                      and standby pumps
                                                                                         DHW heat exchangers
                                                                                         and thermal storage water
                                                                                         circulation and standby pumps
                                                            \
                                         Tr
                                                                 Ts
                                                                          VI, 1    VI, 2
                                                           Generator and electronics coolers
                                   Qfuel, Btu/scf
                                                  Vfuel, scfm
I	1	_JL_
             kW (
                            Heat rejection
                            air handling unit
                             Heat rejection
                             and standby
                             pumps
                                                                        ID?
                                                                                             	i
                                                                                             *") kW !
                                                                     • Electrical lines

                                                                      Building water or
                                                                      heat transfer fluid lines
                                                                  Electrical panel ID


                                                                 ]  Test instrumentation
                                                             ™ ™ ™  Natural gas lines

                      Figure 2-2. Long-term Monitoring Period Instrument Locations

     Water  serves  as  the  CHP  heat  transfer fluid.   Southern will temporarily install supply  and return
     temperature sensors and an ultrasonic fluid flow meter at locations Ts, Tr, and Vli, as shown in Figure 2-2.
     The host site has a paddlewheel  flow sensor at location V12.  Southern will monitor this flow meter's
     output during the long-term monitoring period as a crosscheck.

     Electrical  efficiency determinations  require acquisition of natural gas LHV  data.  Test personnel will
     collect a round of gas samples during the controlled test period and a second round at the end of the long-
     term monitoring period. Analysts will use the mean of all valid samples in the  efficiency calculation.

     Gas consumption will be determined by a datalogger connected to a revenue-grade gas meter. Southern
     will temporarily install a Dresser brand Roots meter, model 11M175, in the CHP array gas line. This
     meter will incorporate a high-frequency pulse output for flow rate determinations. Test personnel will
                                                     2-3

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   Final
July, 2008
connect the meter output to the datalogger and record the gas flow rate at least once per minute during all
test periods.
2.1.3.   Instrument Specifications
The generic protocol provides detailed specifications for all instruments or analyses. Table 2-1 provides a
synopsis while Table 2-2 provides additional details.
Table 2-1. Instrument and Analysis Accuracy Specifications"
Parameter
Voltage
Current
Real Power
Reactive power
Frequency
Power Factor
Voltage total harmonic distortion (THD)
Current THD
Current transformer (CT)
CT
Temperature
Barometric pressure
Gas flow
LHV analysis by ASTM D1945 [2] and D3588 [3]
Heat transfer fluid flow
Tsuppiy, Tretum temperature sensors
Gaseous emissions concentrations
Method 2 volumetric flow rate
Accuracy
+ 0.5 %
+ 0.4 %
+ 0.6 %
+ 1.5 %
+ 0.01 Hertz (Hz)
+ 2.0 %
+ 5.0 %
+ 4.9% to 360 Hz
+ 0.3% at 60 Hz
+ 1.0% at 360 Hz
±1 °F
±0.1 inches of mercury (± 0.05
pounds per square inch,
absolute)
+ 1.0%6
+ 1.0 %
+ 1.0%
+ 0.6 °F
+ 2.0%ofspanc
+ 5.0 %
"All accuracy specifications are percent of reading unless otherwise noted.
^Utility gas meter is temperature- and pressure-compensated.
CPEMS conforms to or exceeds Table 1 of Title 40 CFR 1065.915 specifications.
                                                2-4

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July, 2008
Table 2-2.
Instrument Descriptions and Locations
Index
1
2
3
4
5
6
7
8
9
ch_ro
(channel
identifier)
01
02
03
04
05
06



Parm_ID
(parameter
identifier)
Flow_l
Flow_2
Ts
Tr
Chill_kW
Fuel
Fuel_LHV
Pwr_Gen
Pwr_Par
Description
Heat transfer fluid (water) flow rate
Heat transfer fluid (water) flow rate
Supply temperature
Return temperature
Chiller CHP pump (P-H-CGD-3) and
standby pump (P-H-CGD-4) parasitic load
real power
Natural gas consumption, 0.025 scf per pulse
Natural gas lower heating value
Generated real power, reactive power, power
factor, voltage, current, frequency, total
harmonic distortion
Parasitic load real power consumption
Nominal rating /
expected value
180 gallons per
minute (gpm)
ISOgpm
80 - 140 °F
80 - 140 °F
« 6 kW, maximum
(7.2 A/ph)
111 Hz at 600 kW
910 British thermal
units per standard
cubic foot (Btu/scf)
100kW-600kWe
«38 kW, maximum
(46 A/ph)
Location
Outlet of CHP circulation pump
and standby pump (P-H-CGD-
l,P-H-CGD-2)
Existing: Outlet of CHP
circulation pump and standby
pump (P-H-CGD-1, P-H-CGD-
2)
Outlet of CHP circulation pump
and standby pump (P-H-CGD-
1,P-H-CGD-2)A
Heat transfer fluid return line to
Tecogen array*
MCC-1 40-amp breakers'1
Revenue gas meter
Revenue gas meter
Single module disconnect''
P-COGENbus"
MCC-2 main bus
Sensor manufacturer, model
number
Hedland model HTTN large pipe
ultrasonic flowmeter
Onicon model F- 1 1 1 0
paddlewheel flow meter"
Omega PR-14-3-100 4-wire
resistance temperature device
(RTD)
Omega PR-14-3-100 4-wire RTD
Flex-Core WL-55 watt meter with
(3) Flex-Core 191-151 solid-core
CTs
Dresser CEX
Empact Analytical sampling
bottles
Power Logic ION 7500 with (3)
Flex-core 606-201 split-core CTsd
and (3) Flex-core 19-801 solid-
core CTs"
Power Logic ION 7600 with (3)
Flex-core 606-401 split-core CTs
"To be cross-checked against the National Institutes of Standards and Technology (NIST)-traceable ultrasonic flow meter
*Will require installation of %" inner diameter thermowell for temperature sensor
cRoute the A-phase for each motor through the "A" CT, the B-phases through the "B" CT, and the C-phase through the "C" CT (two phase conductors per CT)
^Controlled test
"Long-term monitoring period
                                                    2-5

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2.2.  SITE-SPECIFIC CONSIDERATIONS

Section 6.0  of the generic protocol lists  step-by-step procedures for the  controlled test period.  This
subsection considers site-specific testing,  safety, or other actions which the field team will implement.
Appendix A of this test plan provides the necessary field data forms.

Emissions testing

Southern will coordinate hoisting the PEMS, heated umbilical, calibration gases, and power supply to the
roof for the controlled tests. This may require rental of a personnel lift.

The 3" diameter exhaust stacks for each  CHP module exit the building through the roof.  Each stack
terminates in a U-bend  section located about 24" above the roof surface.  Test personnel will temporarily
install  an elbow, a horizontal 30" stack extension, and the PEMS exhaust flow and sampling tube at the
stack mouth of the selected CHP module during the controlled test period.  The stack extension will
provide 10 upstream diameters to the closest disturbance, as recommended by the PEMS manufacturer. It
will rest on metal or brick supports to protect the roof surface from heat.

Electrical power monitors

Southern will coordinate the temporary installation of the electric power sensors by a qualified electrician.
The generic protocol, Figure F-l of Appendix F2, provides a wiring schematic.  Southern will provide the
power  monitors, shorting switches, current transmitters  (CT), and miscellaneous supplies.  These tests
will employ both  split-core and solid-core CTs.  The  electrician must remove and reinstall the bus
conductors for the solid-core CTs.  The power meters will require direct voltage connection to each phase.
The electrical feeds must be shut down briefly during the connection procedure and while installing the
CTs and voltage connections.

Natural gas sampling

Southern will collect at least  three natural  gas  samples  during the controlled test period and three
additional samples at the end of the long-term monitoring period.  Southern  will coordinate installation of
sampling petcocks if required. The expected 12 - 20 inches of water column (" H2O) pressure will require
the use of Southern's low pressure gas sampling pump  and manifold.  Test personnel will temporarily
connect the sampling manifold  inlet to the petcock. They will connect an evacuated sample bottle to the
outlet port and purge the bottle  for at least 60 seconds prior to capping and  sealing during each sampling
event.   Analysts will compare the mean  LFfV between the two sets of samples to evaluate potential
changes in the gas supply.  They will also  use the mean LFfV in  the electrical and CHP efficiency
determinations. Appendices A6 and A7 provide a sampling log and chain of custody form, respectively
                                              2-6

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   Final                                                                             My, 2008
                                   3.0  DATA QUALITY

Southern operates the GHG Technology Center for the EPA ETV program. Southern's analysis and QA /
QC procedures  conform to the Quality Management Plan, Version  1.4, developed for the GHG
Technology Center.
3.1.  DATA ACQUISITION

Test personnel will collect the following electronic data files:
       •   power output and power quality parameters
            o ION 7500 power meter database
       •   parasitic loads
            o ION 7600 power meter database
            o Flex-Core WL-55 watt meter connected to datalogger
            o clamp-type real power meter for manual measurements of controls power consumption
       •   emissions concentrations (controlled test only)
            o PEMS
       •   heat transfer fluid temperature and flow rate
            o datalogger
       •   long-term monitoring period fuel consumption (if gas meter pulse output is available)

The power meters and datalogger will poll their sensors once per second during the controlled test period.
The power meters will then calculate and record one-minute averages.  The  field team leader will
download the  one-minute power meter and one second datalogger data directly to  a laptop computer
during the short-term tests.

Test personnel will adjust the  datalogger logging interval to 10 seconds at the start of the  long-term
monitoring period.  A telephone line or wireless  connection will allow Southern to  download the data
files on a weekly basis from the datalogger and power meters during the long-term monitoring period.

Test personnel will record printed or written documentation on the log forms provided in Appendix A,
including:
    •   daily test log, including test run starting and ending times, notes, gas meter readings, etc.
    •   appendix A forms which show the results  of QA / QC checks
    •   copies of calibrations and manufacturers' certificates

The GHG Center will archive all electronic data, paper files, analyses, and reports at their Durham, NC
office in accordance with their quality management plan.
3.2.  DATA QUALITY OBJECTIVES

The generic protocol [1] provides the basis for the data quality objectives (DQO) to be achieved in this
verification. Previous DG / CHP verifications and peer-reviewed input from EPA and other stakeholders
contributed to the  development of those specifications.  Tests which meet the following  quantitative
DQOs will provide an acceptable level of data quality to meet the needs of technology users and decision-
                                              3-1

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   Final                                                                              My, 2008
makers.  The DQO specifications are in terms of relative measurement uncertainty.  The DQOs do not
address sampling variability.
               Verification Parameter                        DQO (relative uncertainty)
               electrical performance as generated power             ±2.0%
               electrical efficiency                                 ±2.5%
               CHP thermal efficiency                              ±3.5%

Each  test measurement that  contributes to a verification  parameter has stated measurement  quality
objectives (MQO) which, if met, ensure achievement of that parameter's  DQO.  Table 2-2 summarizes
the generic protocol MQOs  as accuracy specifications for each instrument or measurement.

The gaseous emissions DQO  is qualitative  in that this verification will produce emission rate data that
satisfies the QA / QC requirements for EPA Title 40 CFR 1065 field test  methods [4]. The verification
report will provide sufficient documentation of the QA / QC checks to evaluate whether the qualitative
DQO was met.

The completeness goal for  this verification  is to  obtain valid data for 90 percent of each controlled test
period and 80 percent of the long-term monitoring period.

A fundamental component  of all verifications is the reconciliation of the collected data with its DQO.
The DQO reconciliation will consist of evaluation of whether the stated methods were followed, MQOs
achieved, and overall accuracy is as specified in  the generic protocol and  this test plan.   The field  team
leader and project manager will initially review the collected data  to ensure that they are valid and
consistent with expectations. They will assess the data's accuracy and completeness as they relate to the
stated QA / QC goals. If review of the test data shows that QA  / QC goals were not met, then immediate
corrective action  may be feasible, and will  be considered by the  project  manager.  DQOs will  be
reconciled after completion of corrective actions.  As part of the internal audit of data quality, the GHG
Center QA Manager will include an assessment of DQO attainment.
3.3.   DATA REVIEW, VALIDATION, AND VERIFICATION

The project manager will initiate the data review, validation, and analysis process. Analysts will employ
the QA / QC criteria specified in §3.5 to classify all collected data as valid, suspect, or invalid.

In general, valid data results from measurements which:
    •   meet the specified QA / QC checks
    •   were collected when an instrument was verified as being properly calibrated
    •   are  consistent  with reasonable  expectations,  manufacturers'  specifications,  and
        professional judgment

The report will incorporate all valid data.  Analysts may or may not consider suspect data, or it may
receive special treatment as will be specifically indicated.  If the DQO cannot be met, the project manager
will decide to continue the test, collect additional data, or terminate the test and report the data obtained.

Data review and validation will primarily occur at the following stages:
    •   on site ~ by the field team leader
    •   upon receiving subcontractor or laboratory deliverables
                                               3-2

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   Final
July, 2008
        before writing the draft report ~ by the project manager
        during draft report QA review and audits ~ by the GHG Center QA Manager
3.4.   INSPECTION AND ACCEPTANCE OF SUPPLIES, CONSUMABLES, AND SERVICES

Procurement documents shall contain information clearly describing the item or service needed and the
associated technical and quality requirements. Consumables for this verification will primarily consist of
NIST-traceable calibration gases.  Fuel analysis will be the only purchased service.  The procurement
documents  will specify the QA / QC requirements  for which the  supplier is responsible and  how
conformance to those requirements will be verified.

Procurement documents shall be reviewed for accuracy and completeness by the project manager and QA
manager. Appropriate measures will be established to ensure that the procured items and services satisfy
all stated requirements and specifications.
3.5.  CALIBRATIONS AND PERFORMANCE CHECKS
Sections 7.1 through 7.3 of the generic protocol specify a variety of technical system audits and QA / QC
checks for the electrical performance, electrical efficiency, and CHP performance determinations.  This
test campaign will perform those that are applicable to the host facility.  The final test report will cite the
results for each QA / QC check.

The generic protocol specifies Title 40  CFR 60 Appendix A source test methods to determine gaseous
pollutant emissions.  This test campaign, however, will employ a Horiba OBS-2200 PEMS that meets
Title 40  CFR 1065  [4] specifications.   Southern will also deploy a Testo  350 multi-gas combustion
analyzer as a backup instrument.  Test  personnel will conduct the technical system audits, calibrations,
performance checks, and cross checks listed in Table 3-1.
Table 3-1. Recommended Calibrations and Performance Checks
System or Parameter
Pressure transducers
Temperature
transducers (Tintajje,
Texh, Ts, Tr)
CHP heat transfer
fluid flow meter
All instrumental
analyzers
CO2 (NDIR detectors)6
CO (NDIR detectors)
Hydrocarbon analyzer
(FID)C
NOX analyzer
NOX analyzer
Description / Procedure
Cross-check with NIST-traceable"
transfer standard
Ice bath / boiling water bath
(adjusted for altitude) cross check
NIST-traceable" calibration
1 1 -point linearity check
H2O interference
CO2, H2O interference
Propane (C3H8) calibration
FID response optimization
C3H8 / methyl radical (CH3)
response factor determination
C3H8 / CH3 response factor check
O2 interference check
CO2 and H2O quench (CLD/
Non-methane hydrocarbons
(NMHC) and H2O interference
(NDUV detectors)6
Frequency
Within 12 months
Within 12 months
Within 12 months
Within 12 months
Within 12 months
Within 12 months
Meets
Spec.?
D
n
n
n


n
n

rj
n
n

Date
Completed













                                             3-3

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   Final
July, 2008
Table 3-1. Recommended Calibrations and Performance Checks
System or Parameter
NOX analyzer
Complete PEMS
Testo (if used)
Exhaust gas or intake
air flow measurement
device
Description / Procedure
Ammonia interference and NO2
response (zirconium dioxide
detectors)
Chiller NO2 penetration (PEMS
with chillers for sample moisture
removal)
NO2 to NO converter efficiency
Comparison against laboratory CVS
system
Zero / span analyzers (zero < + 2.0
% of span, span < + 4.0 % of point)
Perform analyzer drift check (< +
4.0 % of cal gas point)
NMHC contamination check (< 2.0
% of expected cone, or < 2 ppmv)
100 ppm CO cal gas crosscheck
with Testo
Zero / span analyzers (zero < + 2.0
% of span, span < + 4.0 % of point)
Perform analyzer drift check (< +
4.0 % of cal gas point)
100 ppm CO cal gas crosscheck
with PEMS
Differential pressure line leak check
(delta-P stable for 1 5 seconds at 3
" H20)
Frequency
Within 12 months
Within 6 months or immediately
prior to departure for field tests
At purchase / installation; after
major modifications
Before and after each test run
After each test run
Once per test day
At least once per test day
Before and after each test run
After each test run
At least once per test day
Once per test day
Meets
Spec.?
n
n
n
n
Refer to
Appendix
A2, "Test
Run
Record"
n
n
n
n
Date
Completed












"National Institutes of Standards and Technology (MIST)
*non-dispersive infrared (NDIR)
cflame ionization detector (FID)
^chemiluminescence detector (CLD)
"non-dispersive ultraviolet (NDUV)
3.6.  AUDITS OF DATA QUALITY

The  reported results  will include many contributing  measurements  from numerous  sources.  Data
processing will require different algorithms, formulae,  and other procedures.  Original datalogger text
files, power meter database Excel-format file outputs, signed logbook entries, signed field data forms, and
documented laboratory analyses for fuel LHV will be the source for all Excel worksheets used as analysis
tools. The GHG Center QA manager will:
       •   manually check the formulae and results for each data stream from raw data to results
       •   compare the spreadsheet results with data that is reported in the draft report
       •   in the event that errors are found, the auditor will track problems to their source and
           resolve the errors.

3.7.  INDEPENDENT REVIEW

The GHG Center QA manager will examine this test plan, the report text, and all test results. The analyst
or author who produces a result table or text will submit it (and the associated raw data files) to him or to
an independent technical or editorial reviewer.  Reviewers will be Southern employees with different
lines of management supervision and responsibility from those directly involved with test activities.
                                              3-4

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   Final                                                                               My, 2008
                               4.0  ANALYSIS AND REPORTS

The test report will summarize field activities and present results. Attachments will include sufficient raw
data to support the findings and allow reviewers to assess data trends, completeness, and quality.  The
report  will  clearly  characterize the test  parameters, their results,  and supporting measurements as
determined during the test campaign.  It will present raw data and analyses as tables, charts, or text as is
best suited to the data type.

The report will group the results separately for the controlled test runs and long-term monitoring period.

Reported results will include:

       •   run-specific mean, maximum, minimum, and standard deviation
       •   run-specific assessment of the permissible variations within the run for the controlled
           test period
       •   overall mean, maximum, minimum, and standard deviation for all valid test runs
       •   ambient conditions (temperature, barometric pressure) observed during each
           controlled test run
       •   description of measurement instruments and a comparison of their accuracies with
           those specified in the generic protocol
       •   summary of data quality procedures, results of QA / QC checks, the achieved
           accuracy for each parameter, and the method for citing  or calculating achieved
           accuracy
       •   copies of fuel analysis and other QA documentation, including calibration data
           sheets, duplicate analysis results, etc.
       •   results of data validation procedures including a summary of invalid or suspect data
           and the reasons for the validation status
       •   information regarding any variations from the procedures specified in this test plan
       •   narrative description of the DG installation, site operations, and field test activities
           including observations of site details that may impact performance. These include
           thermal insulation presence, quality, mounting methods that may cause parasitic
           thermal loads etc.

The following subsections itemize the reported parameters.  Appendix D of the generic protocol provides
the relevant definitions and equations.

4.1. ELECTRICAL PERFORMANCE

The electrical performance test reports will include the mean:

       •   total real power without external parasitic loads, kW
       •   total reactive power, kilovolt-amperes reactive
       •   total power factor, percent
       •   voltage (for each phase and average of all three phases), volts (V)
       •   current (for each phase and average of all three phases), amperes (A)
       •   frequency, Hertz (Hz)
       •   Voltage total harmonic distortion (THD) (for each phase and average of all three
           phases), percent
                                               4-1

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   Final                                                                                My, 2008
        •   Current THD (for each phase and average of all three phases), percent
        •   real power consumption for the external parasitic loads, kW
        •   total real power including debits from all external parasitic loads, kW


4.2.  ELECTRICAL EFFICIENCY

Electrical efficiency test reports will include:

        •   electrical generation efficiency (rje,LHv) without external parasitic loads
        •   electrical generation efficiency (rje,LHv) including external parasitic loads
        •   heat rate (HRLHv) without external parasitic loads
        •   heat rate (HRLHv) including external parasitic loads
        •   total kW
        •   heat input, British thermal units per hour (Btu/h) at a given electrical power output
        •   fuel input, standard cubic feet per hour (scfh)

The report will quote all laboratory analyses for the fuel LHV in Btu/scf.

Note that electrical generation efficiency uncertainty will be reported in absolute terms. For example, if
T|e,LHv for gaseous fuel is 26.0 percent and all measurements meet the accuracy specifications, the relative
error is ± 3.0 percent  (see generic protocol Table 7-4).  The absolute error is 26.0 times 0.030, or ± 0.78
percent.  The report, then, will correctly state TI^LHV as "26.0 ± 0.8 percent".

4.3.  CHP THERMAL PERFORMANCE

The thermal performance report for the CHP system in heating service will include the mean:

        •   thermal performance (Qout), Btu/h
        •   thermal efficiency (rjth)LHv)
        •   total system efficiency (rjtot)LHv) as the sum of rjth)LHv and rjejLHv
        •   heat transfer fluid supply and return temperatures, degrees Fahrenheit (°F), and flow
           rate, gallons per minute (gpm)

The report will cite the achieved accuracies for r|th and r|tot in absolute terms


4.4.  ATMOSPHERIC EMISSIONS

Reported parameters for each test run will include the following:

        •   emission concentrations for CO, NOX, and THC evaluated in volume parts per
           million (ppmv) corrected to 15 percent oxygen (O2)
        •   emission concentration for CO2 corrected to  15 percent O2
             o Note:  the correction equation  is:
             o
                              "20.9-15
                                               4-2

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Final                                                                             My, 2008
            Where:
                   Ccorr =  concentration corrected to 15 percent O2, ppmv or percent
                   Q = mean concentration of the constituent i, ppmv or percent
                   20.9 = atmospheric O2 content, percent
                   O2 = mean exhaust gas O2 content, percent
        emission rates for CO, CO2, NOX, and THC evaluated as pounds per hour and
        normalized to generated power as pounds per kilowatt-hour
        exhaust gas dry standard flow rate, actual flow rate, and temperature
        exhaust gas composition, moisture content, and molecular weight
                                           4-3

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Final
July, 2008
                                           [Blank Page]
                                               4-4

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   Final                                                                           My, 2008
                                    5.0   REFERENCES

[1]   Generic Verification Protocol — Distributed Generation and Combined Heat and Power Field
Testing Protocol,  Version 1.0, SRI/USEPA-GHG-GVP-04,  Southern Research Institute and US EPA
Environmental Technology Verification (ETV) Program, available at:
, Washington, DC  2005

[2]  ASTM D1945-98—Standard Test Method for Analysis  of Natural Gas by Gas Chromatography.
American Society for Testing and Materials, West Conshohocken, PA. 2001

[3]   ASTM  D3588-98—Standard Practice for Calculating  Heat Value,  Compressibility  Factor, and
Relative Density of Gaseous Fuels.  American Society for Testing and Materials, West Conshohocken,
PA. 2001

[4]  Engine-Testing Procedures,  Title 40 CFR 1065,  Environmental Protection Agency,  Washington,
DC,  adopted at 70 FR 40410, 13 July, 2005
                                             5-1

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Final
July, 2008
                                          [Blank Page]
                                               5-2

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Final                                                                        My, 2008
                                    Appendix A
                                  Field Data Forms

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   Final
                                                                      July, 2008
                    Appendix Al: Distributed Generator Installation Data
Project Name: NYSERDA Tecogen 12494.02
Compiled by: (Company)	
                                   Signature:
                                                  Date:
Address 1:
Address 2:
                        Site Information
                            Owner Company:
                            Contact Person:
City, State, Zip:
Op'r or Technician:
Site Phone:
                           Address (if different):
                           Company Phone: 	
          Fax:
Modem Phone (if used):
Altitude 510 (feet)
                           Utility Name: National Grid
                           Contact Person:
            Utility Phone:
Installation (check one):  Indoor	Outdoor	Utility Enclosure	Other (describe)
Sketch of HVAC systems attached (if Indoor)	Controls: Continuous	Thermostatic
                                                                  Other
Primary Configuration, Service Mode, and CHP Application
(check all that apply; indicate secondary power and CHP application information with
an asterisk, * )
Delta
Single Phase
Inverter
Grid Parallel
Demand
Management
Hot water
Indirect chiller









Wye
Three Phase
Induction
Grid Independent
Prime Power
Backup Power
Steam







Grounded Wye

Synchronous
Peak Shaving
Load Following
VAR Support
Direct-fired chiller







Other DG or CHP (describe)

Date:
                   Generator Nameplate Data
_Local Time (24-hour): 	 Hour meter:
Commissioning Date:
Manufacturer:
                    Model:

Site Description
(Check one)
Hospital
University
Resident' 1
Industrial
Utility
Hotel






Other (desc.)
Office
building








Fuel
(Check one)
Nat'l Gas X
Biogas
Landfill G
Diesel #2
Other (desc.)



Serial #:
Prime mover (check one): 1C generator	 MTG
Range: 	to	 (kW; kVA) Adjustable? (y/n)	Power Factor Range:	to	  Adjustable? (y/n)
Nameplate Voltage (phase/phase):
                   Amperes: 	Frequency:
 Hz
Controller (check one): factory integrated	 3rd-party installed	 custom (describe)_
                                                A-l

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   Final
                                                                                          July, 2008
                   Appendix Al: Distributed Generator Installation Data (cont.)
                                         CHP Nameplate Data
BoP Heat Transfer Fluid Loop

Describe:
Nominal Capacity:
                          (Btu/h)  Supply Temp.
                           (°F)  Return Temp.
Low Grade Heat loop
Describe:
Nominal Capacity:
                          (Btu/h)  Supply Temp.
                           (°F)  Return Temp.
Chilling loop

Describe:
Nominal Capacity:
(Btu/h)  Supply Temp.
                                                       (°F) Return Temp.
Other loop(s): Describe:
Nominal Capacity:
                                 (Btu/h)  Supply Temp.
                                  (°F) Return Temp.
                                           Parasitic Loads

Enter nameplate  horsepower and estimated power consumption.  Check whether internal or external.   Internal
parasitic loads are on the DG-side of the power meter. External parasitic loads are connected outside the system
such that the energy production power meter does not measure their effects on net DG power generation. Additional
power meters or procedures are required to quantify external parasitic loads.
Description
CHP heat transfer fluid pump, one per CHP module
generator / electronics coolant pump, one per CHP
module
generator / electronics coolant pump, 2 incl. spare
generator / electronics coolant air handling unit
CHP heat transfer fluid pump to chillers, 2, incl. spare
CHP heat transfer fluid pump to DHW and hydronic
heating, 2, incl. spare
energy rejection circulation pump, 2, incl. spare
energy rejection air handling unit
control system"




kW, A, or
hp
n/a
n/a
O.Shp
6.5 A
5hp
15 hp
3hp
25 hp
O.SkW




Internal
(")

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Final                                                                              My, 2008
                Appendix A2. Power Meter Commissioning Procedure


 1.   Obtain and read the power meter installation and setup  manual. It is the source of the items
     outlined below and is the reference for detailed information.

 2.   Verify that the power meter calibration certificate,  CT  manufacturer's accuracy certification,
     supplementary instrument calibration certificates, and supporting data are on hand.

 3.   Mount the power meter in a we 11-ventilated location free of moisture, oil, dust, corrosive vapors,
     and excessive temperatures.

 4.   Mount the ambient temperature  sensor near to  but outside the direct air flow to the  DG
     combustion air inlet plenum but in a location that is representative of the inlet air. Shield it from
     solar and ambient radiation.

 5.   Mount the ambient pressure sensor near the DG but outside any forced air flows. Note:  This test
     will use the Horiba OBS-2200 ambient pressure sensor.

 6.   Ensure that the fuel consumption metering scheme is in place and functioning properly.

 7.   Verify that the power meter supply source is appropriate  for the meter (usually 110 VAC) with
     the DVM and is protected by a switch or circuit breaker.

 8.   Connect the ground terminal (usually the "Vref' terminal)  directly to the switchgear earth ground
     with a dedicated AWG 12 gauge wire or larger. Refer to the manual for specific instructions.

 9.   Choose the proper CTs for the application. Install them on the phase conductors and connect them
     to the  power meter through a shorting switch to the proper meter terminals. Be sure to properly
     tighten the phase conductor or busbar fittings after installing solid-core CTs.

 10.  Install the voltage sensing leads to each phase in turn.  Connect them to the power meter terminals
     through individual fuses.

 11.  Trace  or  color code each CT and voltage circuit to ensure that they  go to the proper meter
     terminals. Each CT must match its corresponding voltage  lead. For example, connect the CT for
     phase  A to meter terminals IAi and IA2 and connect the voltage lead for phase A to meter terminal
     VA.

 12.  Energize the power meter and the DG power circuits in turn. Observe the power meter display (if
     present), datalogger output, and personal computer (PC) display while energizing the DG power
     circuits.

 13.  Perform the power meter sensor function checks.  Use the DVM to measure each phase voltage
     and current. Acquire at least five separate voltage and current readings for each phase. Enter the
     data on the Power Meter Sensor Function Checks form and compare with the power meter output
     as  displayed on the datalogger output (or PC display), power meter  display (if present), and
     logged data files.  All  power meter voltage  readings must be within 2% of the  corresponding
     digital volt meter (DVM) reading.  All power meter current  readings must be within 3% of the
     corresponding DVM reading.

 14.  Verify that the power meter is properly logging and storing data by downloading data to the PC
     and reviewing it.
                                           A-3

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   Final
                                                                 July, 2008
                     Appendix A2a. Power Meter Sensor Function Checks

Project Name: NYSERDA Tecogen 12494.02   Location (city, state): Verona. NY	
Date:	  Signature:	
OUT Description:.
Tecogen CM-100 1C engine CHP Power output
Nameplate kW:  100
Type (delta, wye):_
Power Meter Mfr:
Wye
Expected max. kW:    100:110 kVA peaking at unit
Voltage, Line/Line:    480	  Line/Neutral:,
        Model:                    Serial No.:
Last NISTCal. Date:
277
Current (at expected max. kW): 12U 130 kVA peaking Conductor type & size: 3/0 «0.65" at unit 600 MCM « 1.14" at bus
Current Transformer (CT) Mfg:    FlexCore	Model:  606-201 at unit: 606-1000 at bus
CT Accuracy: (0.3 %, other): 	 Ratio (100:5, 200:5, other):	200:5 at unit 1000:5 at bus
                                      Sensor Function Checks
Note: Acquire at least five separate readings for each phase.  All power meter voltage readings must be within 2%
of the corresponding digital volt meter (DVM) reading. %Diff = ^PowerMeter/DVM] -1) * 100
Voltage
Date





Time
(24 hr)





Phase A
Power
Meter





DVM





%Diff





Phase B
Power
Meter





DVM





%Diff





Phase C
Power
Meter





DVM





%Diff





Note: Acquire at least five separate readings for each phase. All power meter current readings must be within 3% of
the corresponding DVM reading.
Current
Date





Time
(24 hr)





Phase A
Power
Meter





DVM





%Diff





Phase B
Power
Meter





DVM





%Diff





Phase C
Power
Meter





DVM





%Diff





                                                A-4

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   Final
                                                                 July, 2008
                    Appendix A2b. Power Meter Sensor Function Checks
Project Name:   NYSERDA Tecogen 12494.02   Location (city, state): Verona. NY
Date:	   Signature:	
OUT Description:.
Nameplate kW:	
Tecogen CM-100 1C engine CHP Parasitic loads
          Expected max. kW:_
Type (delta, wye):	Wye      Voltage, Line/Line:   480
Power Meter Mfr:                          Model:
                                                Line/Neutral:
                                            Serial No.:
Last NIST Cal. Date:
Current (at expected max. kW):   40
Current Transformer (CT) Mfg:   FlexCore
                      .Conductor type & size:
                                      Model:
606-201
CT Accuracy: (0.3 %, other):     0.2 %
                    Ratio (100:5, 200:5, other):   200:5
               277
                                     Sensor Function Checks
Note:  Acquire at least five separate readings for each phase. All power meter voltage readings must be within 2%
of the corresponding digital volt meter (DVM) reading. %Diff = (\PowerMeter/DVM\ -1) * 100
Voltage
Date





Time
(24 hr)





Phase A
Power
Meter





DVM





%Diff





Phase B
Power
Meter





DVM





%Diff





Phase C
Power
Meter





DVM





%Diff





Note: Acquire at least five separate readings for each phase. All power meter current readings must be within 3% of
the corresponding DVM reading.
Current
Date





Time
(24 hr)





Phase A
Power
Meter





DVM





%Diff





Phase B
Power
Meter





DVM





%Diff





Phase C
Power
Meter





DVM





%Diff





                                                A-5

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   Final
                                                                                       July, 2008
                         Appendix A3. Horiba OBS-2200 Test Run Record


Project Name: NYSERDA Tecogen 12494.02     Test  ID: CntrlTest        Date:

Site ID: Madison-Oneida BOCES       EquipJD:  	      Run_ID:
Name (printed):
                        Last 11-point Calibration Date:
                                                    Signature:
PEMS   S/N:	
Test Run      Host facility operator name:
Start time (hh:mm:ss; use 24-hour clock):  	
Filename:
                                                              End time:
Describe ambient conditions:

Wind speed (estimate):	
                                     Direction:
  | Fair n Overcast D Precipitation
IMPORTANT:  Refer to the OBS-2200 "..._b.csv" worksheets  after each test run  for the following
entries. Cell references are provided.
Enter "•/" if a parameter is acceptable, "Fail" if it is unacceptable.  Discuss all "Fail" entries and indicate
whether the run is invalid because of them in the Notes below.
PEMS Zero and Span Drift Checks

Analyte


CO
C02
THC
NOX
Cal. Gas
Value and
Span (ppmv
or %)






2 % of Span






S if Zero drift
OK
(< + 2%of
span
Cells D : 16)





4 % of Span






S if Span drift
OK
(< + 4%of
span
Cells J3 : J6)




Parameter
Allowable ambient temperature range
(see _b.csv worksheet Cells Ml 6 : EOF)
Allowable barometric pressure range
(see b.csv worksheet Cells N16 : EOF)
Allowable "Hangup" (NMHC
contamination) (see b.csv worksheet
Cell Z5)
Criteria
within + 10 °F (6 °C) for T^ < 80 °F (27 °C)
within + 5 °F (3 °C) for T^ > 80 °F (27 °C)
within+l"Hg(3.4kPa)
Enter expected THC concentration, ppmv as C
Enter 2 % of expected concentration


"Hangup must be < 2 % of expected concentration
^ifOK




NMHC contamination and background check < 2ppmv or < 2 % of cone. AP line leak check must be stable for 15 seconds at 3"
H2O. Mean Pbar within + 1.0" Hg of mean for all test runs. Mean T^ within + 10 °F of mean for all test runs if Tambis< 80 °F.
Mean T^t, within + 5 °F of mean for all test runs if T^ is > 80 °F. Drift = (Post-test span minus Pre-test span); must be < 4.0 %.

Notes:
                                               A-6

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   Final
                                                                                      July, 2008
Project Name:_
Date:	
                           Appendix A4: Load Test Run Log
        NYSERDA Tecogen 12494.02             Location (city, state):  Verona. NY
SUT Description: Tecogen CM-100 1C engine CHP
Clock synchronization performed (Initials):	
Data file names/locations (incl. path): File:	
                                                 Signature:	

                                                 Run ID:	
                                                 Run Start Time:
Load Setting: %_
     End Time:
kW
IMPORTANT: For ambient temperature and pressure, record one set of readings at the beginning and one at the
end of each test run. Also record at least two sets of readings at evenly spaced times throughout the test run.
B3-1. Ambient Temperature and Pressure
Time (24-hr)





Average
Amb. Temperature,
°F






Ambient Pressure
"Hg






PSIA = " Hg * 0.491






    2.


    3.
    4.


    5.
                                   Permissible Variations
Each observation of the variables below should differ from the average of all observations by less than the maximum
permissible variation.
Acquire kW and Power Factor data from the power meter data file at the end of the test run. Transfer fuel flow data
from the Fuel Flow Log form. Obtain ambient temperature and pressure from Table A3-2 below. Obtain gas
temperature and pressure from Appendix B4.
Choose the maximum or minimum with the largest difference compared to the average for each value.
Use the maximum or minimum to calculate the %Diff for kW, Power Factor, Fuel Flow, and Ambient Pressure:
%Diff = (M'aorMin)-Avllrag/Averag^* 100                 Eqn. B3-1
For Ambient Temperature, Difference =  (Max or Min)-Average
Variable
Ambient air temperature
Ambient pressure
Fuel flow
Power factor
Power output (kW)
Gas pressure
Gas temperature
Average







Maximum







Minimum







%Diffor
Difference







Acceptable?
(see below)







Permissible Variations
Measured Parameter
Ambient air temperature
Ambient pressure (barometric
station pressure)
Fuel flow
Power factor
Power output (kW)
Gas pressure
Gas temperature
MTG Allowed Range
+ 4°F
+ 0.5 %
+ 2.0%"
+ 2.0%
+ 2.0%
n/a
n/a
1C Generator Allowed Range
+ 5°F
+ 1.0%
n/a
n/a
+ 5.0%
+ 2.0%*
+ 5°F*
"Not applicable for liquid-fueled applications < 30 kW.
*Gas-fired units only
                                                   A-7

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   Final
                                                 July, 2008
                          Appendix AS: Fuel Consumption Determination
   Project Name:   NYSERDA Tecogen 12494.02

          Date:
             Location
           (city, state):   Verona, NY

            Signature: 	
 Test Description:   Tecogen CM-100 CHP

   MeterAMfg:  	
Run_ID:

 Model:
LoadkW:

     S/N:
This procedure assumes that the 11M roots meter odometer resolution is 1 scf.  This means that the meter reading
error will be + 1 scf.  Use the following time durations between each meter reading to ensure that the relative meter
reading error will be approximately + 1.0 % throughout the operating range.
Time duration between each odometer reading depends on the CHP array power setting as follows:
# of CHP
modules
online
1
2
3
4
5
6
Norn. kW
50 - 100
200
300
400
500
600
Nom. scfm
11-21
43
64
85
107
128
Minutes
between
readings
8-4
3
2
1
1
1
^used
for this
run






1.  Start the test run by logging an initial gas meter reading and the exact time of day to  1 seconds.  The initial
reading consists of the last 3 or 4 odometer digits. The last digit to the right on the meter reads as "0.01" Ccf. This
means that each integer reading amounts to 1 scf.  The odometer wheel to the right of the last digit has a hash mark
which, when it passes by the window, indicates the exact instant of the integer reading.  Log that time of day by
holding a timepiece next to the odometer and watching for the hash  mark.  Try to be as consistent as possible in
determining where the hash mark crosses the window.
2.  Observe the timepiece  according to the interval specified in the table above.  Log the exact time of day, to 1
seconds, and the meter integer reading when hash mark crosses the window.
3.  Continue until at least 7 complete readings (including the first reading) have been collected.
4.  Perform the calculations as indicated.
Ref. (n)
1 (initial)
2
3
4
5
6
7
8
Odometer
(scf)








Time
(mm:ss.s)








Time
(decimal minutes)
Gas Used (scf)
(Odmn-Odninj)
Elapsed Time
(Time,, - Time^i)
Rate (scfm)
(Gas Used / Elapsed Time)























Average
Standard Dev.
COV(Std.Dev/Avg)










                                                  A-8

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   Final
                                   July, 2008
                               Appendix A6: Fuel Sampling Log
IMPORTANT: Use separate sampling log and Chain of Custody forms for each sample type (gas fuel, liquid fuel,
heat transfer fluid).
Project Name:   NYSERDA Tecogen 12494.02
Date:	
SUT Description: 1C engine CHP array	
Fuel Source (pipeline, digester):   pipeline
Location (city, state):  Verona. NY
Signature:	
Run ID:	 Load Setting: %_
kW
Sample Type (gas fuel, liquid fuel, heat transfer fluid):
Fuel Type (natural gas, biogas, diesel, etc.):	
      gas fuel
    natural gas
Note: Obtain fuel gas sample pressure and temperature from gas meter pressure and temperature sensors or
sampling equipment.
Gas Fuel Samples
Date








24-hr
Time








Run ID








Canister
ID








Initial
Vacuum, "
Hg








Sample Pressure
(from gas meter
pressure sensor or
sampling train
pressure gage)








Sample Temperature
(from gas meter
temperature sensor
or estimated)








                                                A-9

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   Final
                                          July, 2008
                       Appendix A7: Sample Chain-of-Custody Record


Important:  Use separate Chain-of-Custody Record for each laboratory and/or sample type.

Project Name:   NYSERDA Tecogen 12494.02             Location (city, state): Verona. NY
Test Manager/Contractor	Southern Research Institute Phone: 919.282.1050 Fax:  919.282.1060

Address:      5201 International Drive    City,State / Zip:    Durham. NC  27712	

Originator's signature:	Unit description: MTG array

Sample description & type (gas, liquid, other.):	

Laboratory:     Empact Analytical	Phone:  303.637.0150

Address:	365 S. Main            City:    Brighton	
                       Fax:     303.637.7512

                    State:
CO
Zip:   80601
Run ID








Bottle/Canister ID








Sample Pressure








Sample Temp, or
TAvg, (°F)








Analyses Req'd
ASTM 01945,03588







Relinquished by:_
Received by:	
Relinquished by:_
Received by:	
Relinquished by:_
Received by:	
Date:_
Date:_

Date:_
Date:_

Date:_
Date:
Time:.
Time:.

Time:.
Time:.

Time:.
Time:
Notes: (shipper tracking #, other)
                                               A-10

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Final                                                                                  My, 2008
                                         [blank page]
                                            A-ll

-------
Final
July, 2008
                                Appendix B
                         Tecogen CM-100 Specifications
 TECOGEN
              100 kWPremium Power CHP Module
   Features & Benefits

     . lOOkW Continuous/125 kW Peaking

     » Standard/zed Interconnection

     • Black-Stan Grid-Independent Operation

     • Premium Quality Wave Form.Voltage and Power Factor for Special Applications
       (e.g. computer server farms or precision instrumentation)

     • Power Boost for Demand-Side Response

     • Enhanced Efficiency from Variable Speed Operation

     • Simplified Inter-Unit Controls for either Mode of Operation (parallel or standby)

     • Renewable Energy Compatible
                                                          TECOGEN, Inc.
                                                       Over 25 years experience
                                                       in packaged cogencration,
                                                       chillers and refrigeration
                                                       systems

                                                       More than 1,400 operating
                                                       units in the field

                                                       Extensive service network
                                                       with factory-trained
                                                       technicians exclusively
                                                       servicing Tecogen products
                                    B-l

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Final
July, 2008
                               Appendix B, Continued
                           Tecogen CM-100 Specifications
         Specifications:'
Engine Proven Low-Emission Natu.ro/ Gas V-8 Engine, 454 cid, 1000-3000 rpm
Generator Water-Coofcd. Amorphous Metal, Permanent Magnet Generator
Inverter Customized Power Electronics with Patented Topology for Variable Speed and
Standby Operation
Controls TecoNct7** Microprocessor-Based System, Fully Automatic, Fault Monitoring,
Lead/Lag Multiple Unit Conuol, Modbus Networking & Remote
Telecommunications
Electric Output
lOOkW
1 25 kW Peeking
Standalone Electric Capacity 1 25 kVA
Thermal Output
Electric Efficiency
@ LHVof905 Btu/scf
@HHVof 1020 Btu/scf
System Efficiency
@ LHVof90S Btu/scf
@HHVof 1020 Btu/scf
Gas Input
Required Gas Pressure
Hot Water Flow
732,000 Btu/hr
29.4%
26.1%
92.5%
82.1%
1 280 scfh
1 660 scfh Peaking
\ 0-28" we
30 gpm
Maximum Water Temperature 230 ' F
Air Emissions
. NOx
. CO
. VOC
Weight
Base Dimensions
•.Sp^fcaDDoss^Mtochanj..
0.21 Ib/MWh1-
1 .8 Ib/MWh
.48 Ib/MWh
4,500 Ib
7'L x 4'W x 5.5' H n,,vi, * ^-.-^.•- »«od . v,



. j • ', ' • -I 'V 1 '' ' i ^1 -< i ' P ' i- i • i •
To Exhayst After Treatn
& Heat Recovery
T Varia
".-7|

•..=• ::::::::: 	 I**.
lent
nverter
Rectifier ]
i — »- High Quality
We 	 ^ ' . _¥- « * ^ 3-phase'
ncy [ I JT ^MorSOHz
4- 1 ", Power
ji
, Optional DC Input
' | from Auxiliary Device
1 fsct'ar FV, Ssttesy, Fw&* C*(l, ere.,'
J Tecogen, In
wv.-k 45 First Avenu
I 	 *\ Waltham. MA
% Amorphous Meal Generator
-, 781.466.6400
^^^ 7fl1.4fifi.fi4Bfi[
C.
e
02451
fax]
                                       B-2

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