Version 2.4
August 2009
SRI/USEPA-GHG-QAP-46
August 2009
Test and Quality Assurance
Plan
Climate Energy freewatt™
Micro-Combined Heat and Power System
Prepared by:
SOUTHERN RESEARCH
Legendary Discoveries. Leading Innovation.
Greenhouse Gas Technology Center
Operated by
Southern Research Institute
vxEPA
IW5EROA
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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Version 2.4 August 2009
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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Version 2.4
August 2009
Greenhouse Gas Technology Center
A U.S. EPA Sponsored Environmental Technology Verification ( ETr ) Organization
Test and Quality Assurance Plan
Climate Energy freewatt™
Micro-Combined Heat and Power System
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 August 2009
Director
Greenhouse Gas Technology Center
Southern Research Institute
Lee Beck August 2009
APPCD Project Officer
U.S. EPA
Richard Adamson August 2009
Project Manager
Greenhouse Gas Technology Center
Southern Research Institute
Robert Wright August 2009
APPCD Quality Assurance Manager
U.S. EPA
Eric Ringler August 2009
Quality Assurance Manager
Greenhouse Gas Technology Center
Southern Research Institute
Test Plan Final:
August 2009
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Version 2.4 August 2009
TABLE OF CONTENTS
Page
LIST OF FIGURES i
LIST OF TABLES i
ACRONYMS AND ABBREVIATIONS ii
1.0 INTRODUCTION 1-1
1.1. PURPOSE 1-1
1.2. PARTICIPANTS, ROLES, AND RESPONSIBILITIES 1-1
1.3. TEST SCHEDULE 1-3
2.0 TEST PROCEDURES 2-1
2.1. TEST CONCEPTS AND OBJECTIVES 2-5
2.1.1. Controlled Test Period 2-5
2.1.2. Extended Test Period 2-8
2.1.3. Instrument Specifications 2-8
2.2. SITE-SPECIFIC CONSIDERATIONS 2-9
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 3-5
3.7. INDEPENDENT REVIEW 3-5
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 4-3
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
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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
AFUE
APPCD
AWG
BoP
Btu/h
Btu/scf
C3H8
CH3
CHP
Ci
Ccorr
CLD
CO2
CO2
CT
DG
DG / CHP
DHW
DQO
DVM
EP
EPA
EPB
EPMCHP
ETV
op
Fon
FID
Fvn
GHG
gpm
H2O
"H2O
HHI
annual fuel utilization efficiency
Air Pollution Prevention and
Control Division
American Wire Gauge
balance of plant
British thermal units per hour
British thermal units per standard
cubic foot
propane (reference for FID)
methane (reference for FID)
combined heat and power
mean concentration of
constituent i
Mean concentration corrected to
15% O2
chemiluminiscent detector
carbon dioxide
carbon monoxide
current transformer
distributed generation
distributed generation /
combined heat and power
domestic hot water
data quality objective
digital volt meter
electric power
U.S. Environmental Protection
Agency
electric power flow to the boiler
& controls
electric power flow to/from the
generator unit under test
Environmental Technology
Verification
degrees Fahrenheit
gas flow (nth, volumetric)
flame ionization detector
volumetric flow (nth unit)
greenhouse gas
U.S. gallons per minute
water
inches water column
hybrid hydronic integration unit
HI
HR.LHV
Hz
1C
kBtu/h
kW
LHV
MMBtu/h
MQO
NDIR
NDUV
NIST
NMHC
NOX
NYSERDA
O2
PEMS
ph
ppmv
PVC
QA
QA/QC
RTD
scfh
THC
THD
TRO
TSn
UL
V
T|e,LHV
T|th,LHV
Tjtot
hybrid integration unit
heat rate for power generation on a
LHV basis (Btu/kWh)
Hertz (cycles per second)
internal combustion
thousand BTU/h
kiloWatt
lower heating value (fuel gas)
million BTU/h
measurement quality objective
non-dispersive infrared
non-dispersive ultraviolet
National Institutes of Standards
and Technology
non-methane hydrocarbon
nitrogen oxides
New York State Energy Research
and Development Authority
oxygen
portable emissions measurement
system
phase
volumetric parts per million
polyvinyl chloride
quality assurance
quality assurance / quality control
resistance temperature device
standard cubic feet per hour
total hydrocarbons
total harmonic distortion
return fluid temperature (nth unit)
supply fluid temperature (nth unit)
Underwriters Laboratory
Volt (electric potential)
efficiency (%)
fuel:electric power efficiency
(LHV)
fuel:heat efficiency (LHV)
fuel:total output energy (LHV)
in
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DISTRIBUTION LIST
New York State Energy Research and Development Authority
Jim Foster
Climate Energy
Anthony Petruccelli
U.S. EPA Office of Research and Development
Lee Beck
Robert Wright
Southern Research Institute (GHG Center)
Tim Hansen
Richard Adamson
Eric Ringler
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Version 2.2 July, 2009
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 Climate Energy freewatt Micro-Combined Heat
and Power System. The system is a reciprocating internal combustion (1C) engine distributed electrical
generation and combined heat and power (DG / CHP) installation designed and commissioned by Climate
Energy. Heat is captured from the generator engine and passed to domestic heat loads via a closed heat
transfer loop.
Climate Energy has installed a hydronic version of the freewatt system at a private residence in Lake
Ronkonkoma, Long Island, New York. Appendix B provides the freewatt module specifications.
The CHP system provides domestic hot water via an indirectly-heated hot water heater and comfort heat
to the residence via a hydronic heating system. Included in the package is a high efficiency boiler that
provides backup/peak heating and a "hybrid" hydronic system controller that manages the hot water
temperatures delivered to the hydronic system from the boiler/CHP system. The system is connected in
parallel to the electric utility grid, which provides standby and peak power as required.
The system operates on a thermal-load-following mode, in which power is generated only when heat is
called for from the system. The system is configured to enable export of excess power generation to the
grid.
Manufacturer specifications indicate that the recovered energy will supply up to 12 thousand British
thermal units per hour (kBtu/h) to the local heating loads while producing 1.2 kilo Watt (kW) of electric
power. The supplementary boiler can provide up to an additional 190 kBtu/h.
On-site loads include:
• year-round domestic hot water (DHW)
• hydronic space heating during cold weather
The test campaign will determine the emissions performance, electrical performance, thermal recovery
and electrical efficiency of the CHP module during a "controlled test period". An additional "extended
monitoring period" will report thermal recovery, electrical efficiency and will develop an estimate of
energy savings over a period of not less than three months during the heating season.
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 this technology.
1.2. PARTICIPANTS, ROLES, AND RESPONSIBILITIES
Southern Research Institute's (Southern's) Greenhouse Gas (GHG) Technology Center will manage the
test campaign. Responsibilities include:
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• test strategy development and documentation
• coordination and execution of all field testing, including:
• installation, operation, and removal of emissions testing equipment
• providing electrical power monitoring, CHP heat production, and data logging equipment
• 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 residence located in Lake Ronkonkoma, NY will serve as the host facility. The freewatt™ system
was installed by Climate Energy, LLC. Southern will work closely with Climate Energy personnel to
ensure reasonable access to the host home and minimal effects on the residents.
Robert Wright
US LHA APPCD
QA Manager
Lee Beck I
US LPA APPCD
Project Officer
Tim Hansen
GHG Center Director
Eric Ringler
GHG Center QA
Manager
Richard Adamson
GHG Center
Project Manager
Anthony Petruocelli
Climate Energy, LLC,
Kevin Hicks
GHG Center
Field Team Leader
Burl McEndree
Empact Analytical
Figure 1-1: Test Participants
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.
Richard Adamson 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
Kevin Hicks 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
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• 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
If it is deemed necessary an additional field team member may accompany the Field Team Leader.
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.
Anthony Petruccelli of Climate Energy is responsible for the DG / CHP system design and will serve as
the primary contact for the host facility. He will also work with the Southern field team leader to
coordinate test activities.
1.3. TEST SCHEDULE
The host facility's design normally requires that the CHP module follows the thermal load as it varies
throughout the day, switching on when heat is required and off when thermal demand reduces. The
controlled test period, however, will require operations of the CHP module under controlled load
conditions (forced thermal loading) during the test period. Normal operation will resume as soon as this
test period is finished.
Southern will install electric power production and parasitic electric load monitoring as well as heat
transfer fluid flow and temperature monitoring equipment for use during the controlled test period.
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Table 1-1 illustrates the expected sequence of events during the controlled test period. Test dates will be
coordinated with Climate Energy.
Table 1-1: Controlled Test Period
Controlled Test Schedule
jc«i
Travel to area.
Receive equipment
Day 2
[ 1
Orientation & safety
conference.
Mobilize test equipment &
perform preliminary setup.
Hoist emissions monitoring
equipment.
Install errsssions test stack.
1 ratal! fluid flow &
temperature sensors.
Install power measurement
equipment.
Day 3
Complete installation
Perform pfe-run instrument
checks.
Complete one set of three
runs testing CKP only at
full load.
Perform data quality
checks and preliminary
analyses..
;Day4
If necessary perform a
second set of three runs.
Remove emissions
monitoring Instrumentation.
Sat up for extended
monitoring.
Pack for shipment.
Perform data quality
checks and preliminary
analyses on second data
sets (if applicable}.
,Day5
Ship equipment & return to
lab.
The extended test will commence on completion of the controlled test period. Instruments will be
configured for continuous monitoring from Southern Research's facility in Durham, NC. This period will
extend from a period during which no comfort heating load will be required on site (only domestic hot
water) through a substantial portion of the cooling season, during which time the comfort heating load is
expected to dominate. The data collection period will include at least two months of the heating season.
The projected test schedule is illustrated in Figure 1-2.
ID
1
2
3
Task Name
Controilsci Test
Aug2009 Sep 2009 Oel 2009 Nov 2009 Dec 2009 Jan 2010
m
Equipment Removal _
&Ratum
Figure 1-2: Extended Test Period
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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.
The Environmental Technology Verification (ETV) program test of the freewatt combined heat and
power (CHP) system will require the temporary installation of various sensors and instruments. The
schematics presented in Figures 2-1 and 2-2 show generic mechanical and electrical layouts. This
document assumes a hydronic heat demand-driven installation.
Natural Gas
Supply
Natural Gas
System Boundary
S Sample »
Port <
Figure 2-1: Mechanical Instrumentation Schematic
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July, 2009
Table 2-1: Instrument Descriptions and Locations1
Index
1
3
4
6
7
8
9
10
11
12
13
14
15
ch_ro
(channel)
i
02
03
04
05
06
07
08
Lab
Analysi
s
Power
Meter/
Logger
09
010
Oil
Parm_ID
(parameter)
FVI
Tsi
TRI
FGI
FG2
FV2
TS2
TM
Fuel_LHV
EPMCHP
EPB
EPMCHP_in
EPMCHP_out
Description
Heat transfer fluid (water) flow rate
Supply temperature
Return temperature
MCHP Natural gas consumption, 1 00 pulse
per acf
Boiler Natural gas consumption
Main hydronic heating loop flow rate
Main hydronic heating loop supply
temperature
Main hydronic heating loop return
temperature
Natural gas lower heating value
Generated real power, reactive power,
power factor, voltage, current, frequency,
total harmonic distortion
Parasitic load (boiler controls and boiler
circulating pump) real power consumption
including boiler
Consumed real power (extended monitoring
only - see Index (12) above for controlled
test power measurement.)
Generated real power (extended monitoring
only - see Index (12) above for controlled
test power measurement.)
Nominal rating /
expected value
5 gallon per minute
(gpm)
80 - 140 °F
70 - 100 °F
3 1 pulse/min at
1 8,500 Btu/h
144 pulse/min at
80,000 Btu/h
10 gpm
80 - 140 °F
70 - 100 °F
910 British thermal
units per standard
cubic foot (Btu/scf)
1.2kW
0.2 kW, 8.9
pulse/min
0.1kW,4.4
pulse/min
1 .2 kW, 53 pulse/min
Location
Outlet of CHP circulation
pump and standby pump
Outlet of CHP circulation
pump
Heat transfer fluid return
line
Revenue gas meter
Revenue gas meter
Main hydronic loop
Main loop downstream of
last heat source outlet
(supply)
Main hydronic loop
upstream of first heat
source inlet (return)
Gas Sample Port
Generator output
Boiler subpanel
MCHP subpanel
P2 output, same instrument
as Index (14) above.
Sensor manufacturer, model number
Hedland model HTTF1-BA-NN
ultrasonic flow meter (3/4" copper pipe)
Omega SA-RTD-80-MTP 3-wire
surface mount resistance temperature
device (RTD)
Omega SA-RTD-80-MTP 3-wire
surface mount RTD
Invensys R200 with IMAC pulse
converter
Dresser Roots 8C 175
Hedland model HTTF1-BA-NN
ultrasonic flow meter (3/4" copper pipe)
Omega SA-RTD-80-MTP 3-wire
surface mount RTD
Omega SA-RTD-80-MTP 3-wire
surface mount RTD
Empact Analytical sampling bottles
Power Logic ION 7500 with (2) Flex-
core CTY-050A-1 CTs (controlled test
only. See Index (14)/(1 5) below for
extended monitoring.)
WattNode WNB-37-208P with (2)
WattNode CTS-0750-015 split-core CTs
WattNode WNB-37-208P with (3)
WattNode CTS-0750-015 split-core CTs
(PI output)
P2 output, same instrument as Index
(14) above.
1 See Appendix Cl for instrument and manufacturer details.
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Figure 2-2: Electrical One-Line Drawing with Simplified Mechanical
This monitoring scheme will allow separate quantification of MCHP and total heat production. Hydronic
boiler heat production will be the difference between the two. Southern Research Institute (Southern) will
use non-intrusive ultrasonic fluid flow meters and surface-mounted temperature sensors. The flow meters
and temperature sensors will require the installation of %" inner diameter (7/8" outer diameter) copper
tubing metering sections at FVi and FV2 as shown in Figure 2-1. Flow rate at each meter location will be
between 1 and 55 gallons per minute. Measurements will be performed using Hedland ultrasonic flow
meters (see Index 1 and 8 of Table 2-1 and Appendix C). Temperature sensors are surface mounted 3-
wire 100 Ohm platinum RTD type, bonded to the surface of the copper pipe and insulated to prevent
artifacts due to ambient conditions (see Index 3,4,9 and 10 of Table 2-2 and Appendix C)..
System designers have configured the natural gas piping to allow the temporary installation of Southern-
supplied gas meters. The FGi MCHP gas flow measurement instrument (Figure 2-1 and Index 6 of Table
2-1 and Appendix C) will be a Rockwell / Invensys R 200 standard household-type gas meter with top-
mounted 1 %" NPT union-style fittings. The FG2 hydronic boiler gas flow instrument (Figure 2-1 and
Index 7 of Table 2-1 and Appendix C) will be a Dresser Roots meter, model 8C175 with 1 !/2" NPT male
threaded fittings. Figures 2-3 and 2-4 provide photographs and dimensions. Each metering loop will
incorporate shutoff and bypass valves to enable installation and removal of the meters without disrupting
operations. The gas line will include one sample port, !/2" NPT female coupler with a removable plug,
shown as "Gas Sample Port - VS1" in Figure 2-2. Southern will supply the sampling petcock.
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8C175
CTR/TC
CD/TD ...
tEPS/TPS
vcc
VTC
Overall Length
inches mm
14-9/32 363
J&3a2L___4SQ__
16-13/32
16-1/2
16-29/32
417
419
429
Overall Height
inches mm
6 153
- , _,fi-9/3? ifin
6
8-1/16
6
153
205
153
Centertineto
Width (Flange/Flange) Accessory End(CL-AU)
inches mm inches mm
6-3/4 172 11-13/32 290
_ RAId 17P 13-7/1R 341
6-3/4
6-3/4
6-3/4
172
172
172
13-17/32
11-31/32
12-7/32
344
304
310
Request Detailed
Drawing Number
D05451 6-000
D054430-ODO
D054669-000 \
D054236-000
D0541 80-000
Accessory Unit
UngBi
Figure 2-3: (Dresser) Roots 8C175 Gas Meter
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Figure 2-4: Invensys R200 Gas Meter
The circulation pump "P3" in Figure 2-2, is not be considered a parasitic load because all hydronic
heating systems require a circulation pump. The illustrated metering scheme will allow for netting out the
P3 load if desired.
The MCHP exhaust stack is 2" diameter PVC pipe and the hydronic boiler stack is 3" diameter PVC pipe.
Southern will use a portable emissions monitoring system (PEMS) for the exhaust emissions tests. The
PEMS should function effectively with the existing stacks, but temporary installation of test ducts, at least
10 diameters long, may be required.
2.1. TEST CONCEPTS AND OBJECTIVES
The test campaign will consist of a controlled test period and an extended. The controlled test
incorporates emissions testing for the MCHP and hydronic boiler as well as electric power quality,
electrical efficiency and thermal efficiency under controlled conditions. The extended test does not
include emissions monitoring, focusing instead on energy performance under normal operating conditions
over an extended period of time.
2.1.1. Controlled Test Period
The Field Team Leader will be on-site during the controlled test period to perform the following
determinations on the freewatt unit under test:
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• electrical performance (see generic protocol §2.0 for parameters and specifications;
Appendix D1 for definitions and equations)
• electrical efficiency (see generic protocol §3.0 for parameters and specifications;
Appendix D2 for definitions and equations)
• thermal performance (see generic protocol §4.0 for parameters and specifications;
Appendix D3 for definitions and equations)
• Atmospheric emission performance gaseous carbon monoxide (CO), carbon dioxide
(CO2), nitrogen oxides (NOX) and total hydrocarbons (THC) emissions performance
(see generic protocol §5.0 for parameters and specifications; Appendix D4 for
definitions and equations)
The generic protocol recommends testing at 100, 75, 50, and 25 percent of capacity, but the freewatt unit
operates in an on/off mode only. Power levels during the controlled test period will therefore be 100
percent of capacity only. 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. A 10-minute warm-up and
equilibration period will precede each test run.
Southern will coordinate the temporary installation of independent electrical power analyzers on the CHP
unit output bus. Figure 2-1 shows the instrument locations. The analyzers will record the electrical
performance parameters at 1-minute intervals or shorter. These instruments will allow proper
quantification of the generator, circulation and electronics parasitic loads.
Two sets of three measurements electrical, thermal and emissions readings will be performed. In the first,
the boiler will be turned off, so that the only heat source on the system is the MCHP unit. The second set
of electrical, thermal and emissions readings will be performed with the boiler and MCHP systems both
operational. Emission measurements will be performed on the boiler system for this set of three runs.
Three repetitions of measurements under identical conditions will provide data quality and repeatability
checks.
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. The field team will temporarily install the PEMS and flow tube (Figure 2-1, Std
Vol - standard volumetric flow measurement) on the exhaust stack. The mean concentration for each gas
during each individual test run, integrated with 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.
Southern will log natural gas consumption data for the MCHP unit from the Rockwell/Invensys R200 gas
meter (Figure 2-1, FG1) and gas consumption for the boiler unit from the Dresser Roots 8C175 meter
(Figure 2-1, FG2). Both meters provide pulse outputs for collection using data logging equipment. The
field team will also collect natural gas samples for lower heating value (LHV) analysis off-site.
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2.1.2. Extended Test Period
After the controlled test is complete the thermal and power measurement instrumentation will be left on
site, logging data and periodically transmitting the data to the Southern Research lab facility. This will
take place over a period of not less than five months encompassing at least two months of the typical
heating season in New York. The instrumentation that will be removed from the site prior to the extended
test relates to emissions measurements only.
Southern will log natural gas consumption from the MCHP unit and the boiler unit, as well as hot water
supply and return temperatures, circulating flow, and electric power flow, including both production and
consumption.
2.1.3. Instrument Specifications
The generic protocol provides detailed specifications for all instruments or analyses. Table 2-2 provides a
synopsis of measurement accuracies, while Table 2-1, above, provides manufacturer and model number
as well as channel assignments to the data acquisition system (data logger). Appendix C provides
additional details regarding instrument manufacturers.
Table 2-2: 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
T supply, 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%*
+ 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.
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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
level of the roof for the controlled tests. This will require a personnel lift.
The 2" diameter exhaust stacks for the CHP module exit the building through the original chimney. Each
stack terminates in a U-bend section located about 24" above the roof surface. The field team will
temporarily remove the U-bends and install a stack extension with integrated pitot and sampling probe
that is included as part of the Horiba OBS 2000 system. The stack extension will provide 10 upstream
diameters to the closest disturbance, as recommended by the PEMS manufacturer.
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 CTs, eliminating the need to break existing electrical connections. 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 three natural gas samples during the controlled test. 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. The field team
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 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.
Gas utility data for heating values will be collected for the period from before the controlled test to the
end of the extended monitoring period. The values sampled nearest to the controlled test will be
compared to the independent lab analyses. These secondary values will be used in estimating the
variability in the fuel supply and to identify any potential artifacts due to heating value fluctuations.
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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
The field team will collect the following electronic data files:
• power output and power quality parameters
• ION 7500 power meter database (during controlled test only)
• data logger - WattNode™ power meter (power input during idle cycles and output during
generating cycles through the extended monitoring period only)
• parasitic loads
• data logger - WattNode™ power meter
• clamp-type real power meter for manual measurements of controls power consumption
• emissions concentrations
• PEMS
• heat transfer fluid temperature and flow rate
• data logger
The power meters and data logger 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 data logger data directly to a laptop computer.
Extended monitoring data will be periodically collected remotely.
The field team 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-
makers. The DQO specifications are in terms of relative measurement uncertainty.
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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.
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
Lead 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. Under the guidance of
the Project Manager, Southern Research analysts will validate the data, employing 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 laboratory deliverable s
• before writing the draft report ~ by the Project Manager
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• during draft report QA review and audits ~ by the GHG Center QA Manager
During the extended monitoring period, downloaded data files will be checked by analysts against DQOs
and conformance with reasonable expectations of the equipment performance. In case of failure to meet
DQOs or reasonableness checks, potential sources of error will be investigated remotely. If they are
unresolved or instrument/data acquisition equipment failure is determined to be the cause then Southern
Research will arrange for local support or, if necessary, will travel to the site to correct the problem.
Should the data set be reduced and it is determined that meeting the DQOs will require extending the
measurement period, the equipment will continue to be monitored beyond the projected term.
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
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.
3.5.1 Calibration Gases
Calibrations (zero and span) will be performed in the field using Certified Standards with a single point
audit check against EPA Protocol Gases before mobilization and after demobilization. Records will be
maintained of all calibrations and audit checks. Suitable gases will be procured from Airgas Industries.
EPA Protocol Gases are manufactured and analytically certified in strict accordance with the
most recent EPA traceability guideline document entitled "EPA Traceability Protocol for Assay
and Certification of Gaseous Standards ".
Airgas Industries
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. The field team will conduct the technical system audits, calibrations,
performance checks, and cross checks listed in Table 3-1.
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Table 3-1: Recommended Calibrations and Performance Checks
System or Parameter
Pressure transducers
Temperature
transducers (Tsl, TS2,
TRI, TM)
CHP heat transfer
fluid flow meter
All gas analyzers
CO2 (NDIR detectors)6
CO (NDIR detectors)
Hydrocarbon analyzer
(FID)C
NOX analyzer
NOX analyzer
NOX analyzer
Complete PEMS
Testo (if used)
Exhaust gas or intake
air flow measurement
device
Digital Electric Power
Meters
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)"
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 15 seconds at 3
" H2O)
Reverification
Cross-check (0.01A, 0.2 V between
ION qualified meters)
Frequency
Within 12 months
Within 12 months
Within 12 months
Within 12 months
Within 12 months
Within 12 months
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
Reverification - every 10 years
Cross-check - before and after
each field mission
Meets
Spec.?
D
n
D
G
n
D
G
n
D
D
G
D
n
n
D
D
Refer to
Appendix
A2, "Test
Run
Record"
D
D
D
n
n
Date
Completed
"National Institutes of Standards and Technology (NIST)
*non-dispersive infrared (NDIR)
Tlame ionization detector (FID)
dchemiluminescence detector (CLD)
"non-dispersive ultraviolet (NDUV)
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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 data logger 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.
3.8. DATA PACKAGE SUBMISSION
In addition to the draft report a supplementary data package will be submitted to the Project Officer. In
accordance with the Quality Management Plan [5] this package will include:
• Test Report;
• Audit of Data Quality Memo;
• Results of calibrations and instrument performance checks; and
• Analysis spreadsheets with a representative sample data set.
Raw data sets will be maintained by the GHG Center and will be made available to the EPA on request.
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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 from the controlled test 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
• Reported results from both the controlled test and extended monitoring include:
• 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 (for controlled test period) 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)
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current (for each phase and average of all three phases), amperes (A)
frequency, Hertz (Hz)
Voltage total harmonic distortion (THD), percent
Current THD 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 (for both the controlled test period and the extended monitoring period)
will include:
• electrical generation efficiency (r|e LHV) without external parasitic loads
• electrical generation efficiency (rjeLHv) 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 TjeLHv 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 (TI^LHV)
• total system efficiency (r|totjLHv) as the sum of TjthLHv and T^LHV
• 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^ and r|tot in absolute terms.
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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
• Note: the correction equation is:
~ 20.9-15
C = C
*-• wrv *-• I
Where:
ccorr = concentration corrected to 15 percent O2, ppmv or percent
C; = 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
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Version 2.2 July, 2009
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 Dl945-98—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] Quality Management Plan, Version 1.4, March 2003, Southern Research Institute, Greenhouse Gas
Technology Center. Available at:
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Appendix A
Field Data Forms
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Appendix Al: Distributed Generator Installation Data
Project Name: NYSERDA Climate Energy 12494.03 Date:
Compiled by: Southern Research Institute Signature:
Address 1: Not for publication
Address 2:
Site Information
Owner Company: Resident:
City, State, Zip: Lake Ronkonkoma, NY 11779
Op'r or Technician:
Site Phone: Not for publication_
Modem Phone (if used):
Altitude (feet)
Contact Person: _Tony Petrucelli (Climate Energy, LLC)
Address (if different): 93 West St, Medfield MA 02052
Company Phone: _508-359-4500_ Fax:
Utility Name:
Contact Person:
Utility Phone:
Installation (check one): Indoor_X Outdoor Utility Enclosure Other (describe)
Sketch of HVAC systems attached (if Indoor) Controls: Continuous ThermostaticX 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
X
X
X
X
Wye
Three Phase
Induction
Grid Independent
Prime Power
Backup Power
Steam
Grounded Wye
Synchronous
Peak Shaving
Load Following
VAR Support
Direct-fired chiller
X
Other DG or CHP (describe)
Date:
Generator Nameplate Data
_Local Time (24-hour): Hour meter:
Commissioning Date:
Manufacturer:
Site Description
(Check one)
Hospital
University
Resident'l
Industrial
Utility
Hotel
X
Other (desc.)
Office
building
Fuel
(Check one)
Nat'l Gas X
Biogas
Landfill G
Diesel #2
Other (desc.)
Model:
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)_
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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 CHP unit-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 coolant pump
control system
kW, A, or
hp
n/a
n/a
SOW
Internal
(")
v/
v/
v/
External
(")
"To be manually logged with clamp-type real power meter (see field book).
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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 well-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.
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Appendix A2a. Power Meter Sensor Function Checks
Project Name: NYSERDA Climate Energy 12494.03 Location (city, state): Lake Ronkonkoma, NY
Date: Signature:
OUT Description:.
freewatt (Honda 1C engine) CHP Power output
Nameplate kW: 1.2
Type (delta, wye):_
Power Meter Mfr:
Expected max. kW: 1.2kVAatunit
1-ph Voltage, Line/Line: 220 Line/Neutral:_
Model: Serial No.:
Last NISTCal. Date:
Current (at expected max. kW): 5.45A _Conductor type & size: #12 at unit
Current Transformer (CT) Mfg: FlexCore Model:
CT Accuracy: (0.3 %, other): 0.3% Ratio (100:5, 200:5, other):_
110
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 (D VM) reading. %Diff = §PowerMeter/DVM\ — l) * 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
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Appendix A2b. Power Meter Sensor Function Checks
Project Name: NYSERDA Climate Energy 12494.03 Location (city, state): Lake Ronkonkoma. NY
Date: Signature:
DUT Description: freewatt (Honda 1C engine) CHP Power
Nameplate kW:
Expected max. kW:_
Type (delta, wye):_
Power Meter Mfr:
1-ph Voltage, Line/Line: 220
Model:
Line/Neutral:
110
Serial No.:
Last NISTCal. Date:
Current (at expected max. kW): 5.5A
.Conductor type & size:_
Current Transformer (CT) Mfg: FlexCore
Model:
CT Accuracy: (0.3 %, other): 0.3 %
Ratio (100:5, 200:5, other):_
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 (D VM) 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
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Appendix A3. Horiba OBS-2200 Test Run Record
Project Name: NYSERDA Climate Energy 12494.03 Test ID: CntrlTest Date:
Site_ID: Lake Ronkonkoma Residence Equip_ID: Run_ID:
Name (printed):
PEMS S/N:
Last 11-point Calibration Date:
Signature:
Filename:
Test Run Host facility operator name:
Start time (hh:mm:ss; use 24-hour clock):
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 'V 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
CO2
THC
NOX
Cal. Gas
Value and
Span (ppmv
or %)
2 % of Span
v' if Zero drift
OK
(< + 2%of
span
Cells 13 : 16)
4 % of Span
v' if Span drift
OK
(< + 4 % of
span
Cells J3 : J6)
Parameter
Allowable ambient temperature range
(see b.csv worksheet Cells M16 : 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
v'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 Pbal within + 1.0" Hg of mean for all test runs. Mean Tamb within + 10 °F of mean for all test runs if T^t, is < 80 °F.
Mean T^t, within + 5 °F of mean for all test runs if Tamb is > 80 °F. Drift = (Post-test span minus Pre-test span); must be < 4.0 %.
Notes:
A-6
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Version 2.2 July, 2009
A-7
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Version 2.2
July, 2009
Project Name:_
Date:
Appendix A4: Load Test Run Log
NYSERDA Climate Energy 12494.03 Location (city, state): Lake Ronkonkoma. NY
Signature:,
Run ID:
Load Setting: %_
End Time:
kW
SUT Description: freewatt (Honda 1C engine) CHP Power
Clock synchronization performed (Initials): Run Start Time:
Data file names/locations (incl. path): File:
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.
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 = ((MalorMin)-Avemg/Averagl!)*lOO 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 op*
"Not applicable for liquid-fueled applications < 30 kW.
*Gas-fired units only
A-8
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Version 2.2
July, 2009
Appendix AS: Fuel Consumption Determination
NYSERDA Climate Energy
Project Name: 12494.03
Date:
Location
(city, state): Lake Ronkonkoma. NY
Test Description: freewatt-Honda 1C engine Run_ID:
Meter A Mfg: Model:
Signature:
Load kW:
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 (set)
(Odmn - Odmn 0
Elapsed Time
(Time, - Time, J
Rate (scfm)
(Gas Used / Elapsed Time)
Average
Standard Dev.
COV(Std.Dev/Avg)
A-9
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Version 2.2
July, 2009
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 Climate Energy 12494.03 Location (city, state): Lake Ronkonkoma. NY
Date: Signature:
SUT Description: freewatt-Honda 1C engine Run ID: Load Setting: % kW
Fuel Source (pipeline, digester): pipeline
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-10
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Version 2.2
July, 2009
Appendix A7: Sample Chain-of-Custody Record
Important: Use separate Chain-of-Custody Record for each laboratory and/or sample type.
Project Name: NYSERDA Climate Energy 12494.03 Location (city, state): Lake Ronkonkoma, 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: freewatt-Honda 1C engine
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
Relinquished by:
Received by:
Relinquished by:
Received by:
Relinquished by:
Received by:
Bottle/Canister ID
Sample Pressure
Date:
Date:
Date:
Date:
Date:
Date:
Sample Temp, or
TAVS, (°F)
Analyses Req'd
ASTMD1945, D3588
Time:
Time:
Time:
Time:
Time:
Time:
Notes: (shipper tracking #, other)
A-ll
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Version 2.2 July, 2009
[blank page]
A-12
-------
Version 2.2 July, 2009
Appendix B
Hydronic Freewatt System Model 1.2 HDZFN
B-l
-------
Version 2.2
July, 2009
Climate
Energy
freewatt
TECHNICAL SPECIFICATION
Hydronic Freewatt System
Model freewatt-1.2HDZFN
MICRO-COMBINED HEAT AND POWER SYSTEMS
Climate Energy's Freewatt™* System combines two technologies, an advanced boiler and a natural gas-fired engine-generator. This hybrid heat and power
generation package provides unrivaled total energy efficiency in combined heat and power delivery to the home, The ^reewatt7" System is designed to be
installed in the place of a typicaJ boiler and uses the same ductwork system to deliver the heat to the home.
FREEWATT™ SYSTEM FEATURES
• Honda MCHP Power Generation Technology
o Honda Reliable
o Quiet (47 dBA)
o Efficient (B5%+= Heat And Power)
D 1.2 kW of Electric Power Production
o UL1741 Certified for Grid Interconnection
c Proven Technology
o PVC Exhaust Venting
Advanced Boiler
c Energy-Star Qualified
o High Efficiency {95% AFUE)
c Condensing Appliance
Hybrid integration Module
c Permanent Magnet °-jmp
•: Compact Brazed Piate Heat Exchanger
Control Module
i- Freewatt™ System Controller
c Advanced Heat And Power Algorithm
•- Communicating Thermostat
c Internet Connection
Simple Installation
Compatible with Conventional Baseboard and
Radiant Heat Emitters
FREEWATT™ SYSTEM BENEFITS
• Reliable Power Generation, Powered by Honda™
• Significantly Reduces:
c- Home's Carbon Footprint Using Energy Conservation
j Monthly Electric Bill by Net-Metering °ower Generation & Use
• Enhanced Comfort
3 Low Level of Continuous Heat Delivery
Increases house value by $5,000 to $20,000 (National Appraiser's Institute)
Return en Investment (ROI) of up to 20^6 annually
System Monitoring through the Internet Connection
Breakthrough Home Energy Technology
Simplified Grid Interconnection
Heating Zone
Circulators
freewatt Indirect
Hot Water Heater
freewatt Boiler
95% AFUE
Honda MCHP
Exhaust Gas Sensor
Contra! Module
Programs blc &
C (3i nn t unicating
Thermostat
Outdoor Temperature
Sensor
Anjn Boiler Controls
HI Module
Popular
Mechanics
BREAKTHROUGH
AWARDS
2 O O 6
PATH
PARTNER
Honda MCHP
The Boiler and HI Module
assembly is design certified in the
US and Canada by the Canadian
Standards Association.
ENERGY STAR
As an Energy Star paltrier, Climate Energy
has determined that the boiler included as
part of the Freewatt system meets Energy
Star guidelines for energy efficiency.
The Honda MCHP is an Underwriter's
Laboratory (UL) Listed, "UCIity Interactive.
Cogeneraaon. Stationary Engine-Generator
Assembly, File Number FTSR.AU2004 (U.S.)
ana FTSR7.AU2004 (Canada)."
B-2
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Version 2.2
July, 2009
Climate
Energy
freewatt
f*OWLR£L> by
HO1VDA
Hydronic freewatt System
Model freewatt-1.2HDZFN
Engineered for High Efficiency
I Honda MCHP Unit
• Delivers a steady-state efficiency of 85%+ while producing
power and heat, thereby reducing the amount of energy
consumed to generate your power
• Delivers exhaust through PVC Venting
2. Advanced Hot Water Boiler
• Delivers 95% AFUE with a corrosion resistant aluminum
block heat exchanger
• Outdoor reset increases efficiency and indoor comfort
3. Hybrid Integration Module
• Consumes under 30 watts to deliver heat from Honda
MCHP unit to air coil heat exchanger
4 Control Module
• Advanced heat and power algorithm optimizes power
production of Honda MCHP unit
Hydronic freewatt System
Advanced Technology
5. Onboard Inverter
• Integrated inverter delivers high quality power to the
home's main circuit panel
• UL 1741 Certified for Grid Interconnection
6. Exhaust Heat Exchanger
• High efficiency heat exchanger reduces exhaust products
to 140° F, allowing use of PVC venting
• Three-way catalytic converter significantly reduces
emissions
7. Combustion Control System
• Oxygen sensor feedback allows for excellent emissions
control
• Stepping gas valve offers almost unlimited control of
gas:air mixture
Quiet Operation & Comfort
Honda MCHP Unit
• Generates heat & power at a noise level of only 47 dBA
Advanced Hot Water Boiler
• Ultra quiet operation while delivering heat in Low Heat
mode
• Low Heat mode drastically reduces temperature swings
and increases overall comfort
freewatt System
• Low Heat mode - MCHP operates
• High Heat mode - MCHP and furnace operate
Reliability
Honda's commitment to bringing products to market that improve the quality of people's life goes well beyond cars and
motorcycles. Since 1953, Honda has manufactured over 40 million power products worldwide and continues as a leader in the
development of low-emission, fuel efficient, environmentally friendly 4-stroke engines for use several power equipment
applications. Now Honda's unwavering reliability, quality, durability and environmentally conscious efficiency combines with
Climate Energy's Freewatt System to bring micro-combined heat and power to the home.
Honda MCHP Unit
B-3
-------
Version 2.2
July, 2009
aimate freewatt
Energy
F-OWEHED by
HO3VDA
Model freewatt-l.iHDZFN
Typical Hydronic freewatt System Footprint
72"
Model freewatt-1.2HDZFN
Honda MCHP Unit - Std YM2A Model
f,
s
\l
odel freewatt- 1.2HDZFN
ystem Clearances
Dimensions
Top
Left Side
Right Side
Base
Front
Back
Intake/Vent Piping
Near Boiler HW Piping
Boiler
1"
1"
1"
C - Note 1
Z"
t"
0"
1"
Honda
MCHP
20"
12"
12"
B - Note 2
21"
2"
0"
0"
Service
S"
24"
24"
ote: 1. Combustible floor approved, but not carpet,
2. MCHP is attached to base that is anchored to concrete floor.
Hydronic Freewatt System
Model freewatt-1.2HDZFN
CONCRETE FLOOR REQUIREMENTS
THICKNESS T MINIMUM
FLATNESS: K IN 10 FEET CLASS CX
OftOP.m ANCHOR 3(8-00*1 75HONGl5/18M8THftEaOJ QUANTITY
Jjj
Model freewatt-l,2HDZFN
Connections
Boiler
Electrical: 120 Volts AC. 60 Hz, 1 phase, Less than 12 amps
Air Intake/Vent: 3' Sch 40 PVC
Natural Gas: W NPT
Condensate Drain: 1/2" PVC
Internet Connection: RJ45
Honda MCHP
Electrical: 240 Volts AC. 60 Hz, 1 phase, Less than 5 amps
Vent: 2" Sch 40 PVC
Natural Gas: V* NPT w/ flexible connector
Condensate Drain: %" Tube
Consult Installation Manuals for more details.
Model freewatt-1.2HDZFN
Boiler Dimensions 8, Locations
Dimensions
height
Width
Depth
Return Connections
Supply Connection
Exhaust Vent
Air Intake
Fuel Gas
Boiler
39 3/8"
IS''
30 7/8"
Sack/Rig'-t/Uf:
TCP
Top
Back/Left
Back/Right/Left
Model freewatt-1.2HDZFN
Hydronic Hybrid Integration Module Details
( Reservoir Tank
Tempering VoAvc
From Kydronic Ugp
To Hydronic Loop
B-4
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Version 2.2
July, 2009
M HEATING CAPACITIES -NATURAL GAS •
•Model CE95V1-230
E"i:ie-:viA=.:i 95%
Stage 1 - IV-icro-t-P Mcde (Low)
Input (MBH) 0-2,000' 18,5
Cjtput (MBH) 0-2,000' 12.0
Stage 2 - M;n Hea: Mcde High)
Input (MBH) 0-2, 003' SO
Output (MBH) 0-2, 000' 76
Stage 2 - Max Heat Mode (High)
Input (MBH) 0-2,000' 200
Output (MBH) 0-2,000' 190
• BOILER CONNECTION DIMENSIONS •
Supply 1 H"
Seturn 1 K"
| MAXIMUM VENTING LENGTHS [EACHELBOWEQUAISFIVEFHETI M
Venting Length (ft.) - Boiler (3") 100 ft.
Verting Length (ft.) - Honda WCH? (2") 9C ft.
Model freewatt-1.2HDZFN
Typical Roof Vent/lntake Terminations
Consult Installation Manuals for more details.
Model freewatt-l.iHDZf N
Control Module Details
@gSS? Freewatt
o .-—.
Z
m
.,.».„„ i. HONDA
Model freewatt-1.2HOZFIM
Typical Sidewall Vent/Intake Terminations
•'
f J^
nonlli*"1
ga "tf1
OB6M« 1
Consult Installation Manuals for more details.
Model freewatt-l.ZHDZFN
Grid Interconnection
The grid interconnection of the Honda MCHP unit is required to operate the system. Depending on the state's
regulations and the electric utility, different grid interconnection application processes are required. Climate
Energy is actively educating state governments and electric utilities about the benefits of Micro-CHP and how the
freewatt System can be a critical component in their energy conservation portfolio. If any questions surface during
the grid interconnection process, please contact your Climate Energy product technician or Climate Energy at 508-
359-4500.
f-secycling
\ energy
"• PUD It's time
/£) Climate
v*? Energy
For More Information:
www.climate-enerqv.com 1 .508.359.4500
B-5
-------
Version 2.2 July, 2009
Appendix C
Instrumentation and Instrument Manufacturer Data
C-l
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Version 2.2
July, 2009
Parameters
FVI, FV2
Tsi, Ts2, TRI, TR2
FG1
FG2
EPMCHP
CTs for ION 7500
EPe, EPMCHp_m,
EPMCHP out
CTsforWattNodes
Data Logger
Manufacturer
Racine Federated,
Inc.
Omega Engineering
Dresser, Inc.
Invensys
Power Logic (now
Schneider Electric)
Flex-Core, Div. of
Morlan Associates,
Inc.
Continental Control
Systems
Continental Control
Systems
Dataq Instruments,
Inc.
Model
Hedland
HTTF1-BA-NN
3/4"ultrasonic flow
meter
SA-RTD-80-MTP
Roots 8C175
Rockwell R200
ION 7500
Flex-Core
CTY-050A-1
WattNode Pulse
WNB-2Y-208P
CTS-0750-015
Dataq Instruments
Model DI715B
Vendor
Racine Federated,
Inc.
Omega
Engineering, Inc.
Dresser, Inc.
Sensus
Power Logic
Flex-Core
Continental
Control Systems
Continental
Control Systems
Dataq Instruments,
Inc.
Mfr Location
Racine, WI
Stamford, CT
Addison, TX
Raleigh, NC
British
Columbia,
Canada
Milliard, OH
Boulder, CO
Boulder, CO
Akron, OH
C-2
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