Green generation expanded at Thames Long Reach with biogas genset

Finning Power Systems is increasing the amount of green electricity produced by Thames Long Reach sewage plant from 2.3 MW to 3.3 MW with the installation of a third CHP biogas generator. Phase two of the turnkey installation is due for completion later this year.

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The project involves installing and commissioning a customised Cat G3516 biogas generator set as a combined heat and power system, expanding the switchgear with an additional HV board cabled to the existing system and expanding the LIMA remote control and monitoring system.

Finning will also complete any necessary civils work such as building, sound attenuation and additional pipework.

Phase 1 of the turnkey project, to produce electricity from the methane gas produced by the sewage, was also completed by Finning Power Systems.

Now, due to the more efficient generation of methane gas, Thames Water has decided to add a third CHP biogas generator set. Original projections were for 17 000m3 of methane gas. This has since increased to 22 000 m3 and improving the sewage digestion system will further increase the methane available for power generation to 28 000 m3.

The extra electricity produced by the third biogas generator will be used to power the expanded sewage operation and to also export more green power to the national grid. The extra 1MW provides enough electrical power for 200 homes a day.

The aggressive nature of sewage gas means that Finning Power Systems fully hardened the Cat generator set before it was installed. This involved using special lubricants with high temperature cooling jackets.

The current installation provides enough electrical output to power the 1.8MW sewage works load making the plant completely carbon neutral. In addition, the power station can export electricity to the grid depending on the tariff available at the time. A back up diesel generator set provides failsafe power generation if both of the existing biogas generator sets fail and another auxiliary diesel generator provides a third level of back up.

The LIMA control system can switch between generator sets automatically and also prioritize which circuits are powered if there is a problem. Again two levels of redundancy means that generator sets can be switched automatically or manually using LIMA, or manually using key switches. It also allows remote monitoring of the whole system as part of Finning’s 24/7 maintenance contract.

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In addition the methane gas can be stored in double skinned expandable balloon holders so the amount of fuel used, and therefore electrical power generated, can be managed.

The CHP system also generates 2 MW of heat. This heats up the sewage digestors to generate more methane gas for power generation.

Thames project manager, David Watts, said: “When the original power station burnt down in 2000 we decided that it was more energy efficient and environmentally friendly to use the methane gas to generate electricity rather than burn it off.”

“We originally chose Finning for the project because they can supply the complete turnkey solution, not only supplying the customised Cat generator, but also the design, installation and commissioning and full service back up. Phase two of the project will further increase our capacity to generate green electricity.”

Deutz unveils robust new genset

Deutz Power Systems has released a new version of the successful TCG 2020 gas engine, of which 2000 units have so far been supplied, called TCG 2020 OLS (Optimized Load Steps).

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The engine is designed to run exclusively on natural gas and the company said it has been specifically optimized for operation at temperatures above 25 degrees C and altitudes of more than 100 m above sea level. The ISO 3046 allows as a standards procedure to decrease performance when gas engines are operated in environments where these parameters are exceeded.

With the TCG 2020 OLS the Deutz Power Systems still guarantees the full cylinder output, even at air intake temperatures of up to 40 degrees C.

The engine’s mechanical cylinder output is 96.25 kW, resulting in the following electric unit outputs: 1125 kW with the V12 version and 1500 kW the V16 version. According to the manufacturer, the OLS engine permits higher load applications, and is therefore particularly suitable for island operation.

Deutz Power Systems also indicated that, when running on natural gas the OLS engine needs a minimum methane number of 70 in order to be able to reach the full specified load. Deutz Power Systems also extended the servicing intervals for the TCG 2020 OLS, and the major scheduled overhaul is only required after 64 000 operating hours.

Waukesha licenses diesel tech to Kirloskar of India

Waukesha Engine, a business unit of Dresser, Inc, has entered into a licensing agreement with Kirloskar Oil Engines Ltd of India (KOEL), part of the Kirloskar Group.

Under terms of the agreement, KOEL will be licensed to manufacture and sell worldwide, large diesel engines, which are based on the W200 diesel engine technology that Waukesha acquired from Wärtsilä Corporation in 2004.

The W200 diesel engine technology fills a need in Kirloskar’s product line-up, according to Thomas J. Laird, president of Waukesha Engine.

The agreement with Kirloskar includes a licensing fee and allows Waukesha Engine to utilize the diesel technology, while continuing to focus its efforts on the spark-ignited, gaseous-fueled engines that are the core of its business.

The agreement also includes a future option for Kirloskar to build and sell the W220 gaseous-fueled counterpart of the W200 in the India market.

GE launches first 24 cylinder gas engine unit

GE Energy’s Jenbacher gas engine business is presented a world’s first the 4-MW, J624 GS Jenbacher gas engine, which is the first 24-cylinder unit.

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The firm said that its new engine, successfully running on the test bench in Jenbach, represents a quantum leap in gas engine technology and builds on GE’s experience in advanced high-speed gas engine technology for commercial on-site power applications.

The new J624 GS will be built in GE’s recently expanded gas engine manufacturing facilities in Jenbach, Austria, which has been seeing a sharp increase in worldwide demand for power generation with gas engines.

The J624 GS’s new engine and package concept consists of a gas engine mounted on a base frame as well as a vibration-decoupled turbocharger group, which results in lower transmission of engine vibrations to other equipment.

This group includes turbo chargers, heat exchangers with piping and control valves, gas train, gas dosing valve and gas mixer, interface panel, and standardized hydraulic interfaces to the customer.

Volker Schulte, leader of the Research & Development Department for GE’s Jenbacher gas engines, said: “We managed to meet a number of technological challenges in designing this new engine. These include designing both engine and turbochargers for an extremely high mean effective pressure, controlling the vibrations by decoupling the intercooler and turbochargers, optimizing the combustion sequence, and increasing the mechanical strength of the crankshaft. Due to the dedication of all the staff involved in Jenbach, intensive simulations, exhaustive studies, rapid prototyping, and years of cooperation with our suppliers, we were able to achieve this significant step forward in two years.”

For the new J624 GS, GE further enhanced its previously launched Type 6 engine design featuring Miller valve timing, optimized mixture forming and controls, which leads to high efficiency levels and specific output values with high-speed gas engines.