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
-------
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.
-------
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
-------
Final My, 2008
[Blank Page]
-------
Final My, 2008
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
-------
Final
July, 2008
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
-------
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
-------
Final
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
-------
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
-------
Final
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
-------
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
-------
Final
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
-------
Final
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
-------
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
-------
Final
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
-------
Final My, 2008
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
Final
July, 2008
[Blank Page]
4-4
-------
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 D1945-98Standard Test Method for Analysis of Natural Gas by Gas Chromatography.
American Society for Testing and Materials, West Conshohocken, PA. 2001
[3] ASTM D3588-98Standard 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
-------
Final
July, 2008
[Blank Page]
5-2
-------
Final My, 2008
Appendix A
Field Data Forms
-------
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
-------
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
(")
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
-------
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
------- |