Kohler MT80CHP Installation Manual
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Kohler MT80CHP Installation Manual

Kohler MT80CHP Installation Manual

Micro turbine chp
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Installation
Micro Turbine CHP
Models:
MT 80 CHP
TP-6242
8/03

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Summary of Contents for Kohler MT80CHP

  • Page 1 Installation Micro Turbine CHP Models: MT 80 CHP TP-6242 8/03...
  • Page 2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Accessory Number Accessory Description Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued Onsite Installation ........... . . 3.9.1 Gas Safety Train Installation .
  • Page 5 Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting WARNING INSTRUCTIONS. Electromechanical equipment, including generator sets, WARNING transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or Explosion. maintained. To prevent accidents be Can cause severe injury or death.
  • Page 6 Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. fire can cause severe injury or death. Carbon monoxide can cause severe severe injury or death. Battery gases Do not smoke or permit flames or nausea, fainting, or death. Carbon can cause an explosion.
  • Page 7 fuel or fuel vapors. Keep the fuel lines Hazardous Voltage/ Grounding electrical equipment. and connections tight and in good Hazardous voltage cause Electrical Shock condition. Do not replace flexible fuel severe injury or death. Electrocution lines with rigid lines. Use flexible is possible whenever electricity is sections to avoid fuel line breakage present.
  • Page 8 Electrical backfeed to the utility. Servicing transfer switch WARNING Hazardous backfeed voltage can controls and accessories within the cause severe injury or death. Install enclosure. Hazardous voltage can a transfer switch in standby power cause severe injury or death. installations to prevent the connection Disconnect the transfer switch controls of standby and other sources of power.
  • Page 9 Moving Parts Tightening the hardware. Flying NOTICE projectiles can cause severe injury Voltage reconnection. Affix a notice or death. Loose hardware can cause to the generator set after reconnecting WARNING the hardware or pulley to release from the set to a voltage different from the the generator set engine and can cause voltage on the nameplate.
  • Page 10 Notes Safety Precautions and Instructions TP-6242 8/03...

  • Page 11: Introduction

    Information in this publication represents data available alternator via a power conversion stage. The systems at the time of print. Kohler Co. reserves the right to can be configured either with or without exhaust gas change this publication and the products represented...
  • Page 12 Notes Introduction TP-6242 8/03...

  • Page 13: Section 1 General Information

    Section 1 General Information 1.1 Introduction 1.3 General Description The weights of the main components within the Micro The micro turbine may be considered as comprising Turbine system are shown in Figure 1-1. three main functional areas: control and power electronics, engine, and heat recovery.

  • Page 14: Variants

    1.4 Variants Fully Recuperated System The system is fitted with a recuperator that preheats the There are two basic variants of the micro turbine: combustion using turbine exhaust, thereby increasing electrical conversion efficiency. The fully Cogeneration Systems—Fully Recuperated System and Recuperator Bypass System recuperated variant has no recuperator bypass valve.

  • Page 15: Simple Cycle

    1.4.2 Simple Cycle 1.5 Oil Cooling A simple cycle variant does not have the recuperator or In fully recuperated and recuperator bypass systems, heat recovery module. See Figure 1-5. the oil circuit is cooled using return water from the heating system provided this return water temperature Note: All configurations can be cooled using an optional does not exceed 70°C (158°F).
  • Page 16 Notes Section 1 General Information TP-6242 8/03...

  • Page 17: Section 2 Technical Data And Specifications

    Section 2 Technical Data and Specifications 2.1 Performance Specifications 2.2 Mechanical Specifications Parameter Specification 2.1.1 Fully Recuperated System Engine derating As per attached curves following. The following performance specifications consist of Fuel capability Natural gas typical data only and cannot be guaranteed. All values Maximum fuel temperature, °C (°F) 60 (140) are at ISO conditions: 101.3 kPa (14.7 psi), 50_C...

  • Page 18: Electrical Specifications

    2.4 Electrical Specifications 2.4.3 Insulation Test Specification Perform insulation tests according to the supplied 2.4.1 General instructions to prevent damage to the electrical system of the generator set. Parameter Specification Voltage 240/416 volt, 3-phase, 4-wire, 60 Hz, Parameter Specification 80 kW, 100 kVA, 139 amps. output Power circuits 110V...

  • Page 19: Control Specifications

    2.5 Control Specifications 2.7 Available Options Parameter Specification Parameter Specification Remote monitoring and control protocol Modbusr Gas boost See separate gas boost compressor compressor specification. Gas safety 2.6 Standard Product Features See separate gas safety train specification. train Additional An additional I/O board is fitted to all CHP Parameter Specification systems.
  • Page 20 System Waste Heat Recovery Unit Water Pressure Drop Minimum to Maximum Thermal Output 0.08 0.07 0.06 0.05 0.04 System 0.03 0.02 0.01 0.00 2.00 4.00 6.00 8.00 10.00 12.00 Water Flow Rate (L/sec.) Figure 2-1 Heat Exchanger Waterside Pressure Drop/Water Flow Rate Part Load Efficiency Predictions at Constant Speed Power kW Figure 2-2 Predicted Efficiency Curve For Constant Speed Mode...
  • Page 21 Power Derate Curves—Recuperated 50 mm (2 in.) Water Column Inlet Back Pressure, 150 mm (6 in.) Water Column Exhaust Back Pressure 90,000 80,000 Sea Level (A) 70,000 1000 ft. (B) 2000 ft. (C) 3000 ft. (D) 60,000 4000 ft. (E) 5000 ft.(F) 6000 ft.
  • Page 22 Power (kW) Derate for Exhaust Duct Losses ISO Conditions: Ambient Temperature 15°C (59°F), 1013 mBar (14.7 psi) (29.91 in. Hg), Zero Altitude Exhaust Duct Back-Pressure, mm H NOTE: mm H O / 25.4 = in. H Figure 2-5 Exhaust Duct Loss Derate CBEMA Voltage Transient Curve (100% Step Change) 100% 10 seconds...

  • Page 23: Section 3 Installation Requirements

    Section 3 Installation Requirements 3.1 Safety cooling fans, battery charger, and oil heater. This transformer is installed in the control system at Read and follow the Safety Precautions and Instructions manufacture. section of this manual prior to installing the micro An additional transformer must be provided by the user turbine.

  • Page 24: Protection Of Embedded Generators Operating In Utility Mode

    Isolation Bus-Bars Switch & Fuses High Voltage Isolation Other Load Feed Switch & Circuits 400 V Meter Fuses e.g. 11 kV Neutral Protective Ground Micro Turbine Customer Interface Generator Site Distribution Panel Figure 3-2 Utility Mode, Typical Installation Diagram 3.3.2 Protection of Embedded must obtain prior agreement of the utility that these are sufficient.

  • Page 25: Heated Water System

    Current Manual Ground Customer Sensor Isolation Leakage Output Connection Contactor Switch Detection Engine/ Power Filter Alternator Converter Ground Ground Connection Chassis Ground High Voltage Controller Sense Micro Turbine Generator Figure 3-4 Utility Mode Electrical Schematic Ground Fault Protection 3.4 Heated Water System Ground fault protection is fitted internally as standard.

  • Page 26: Recommended Pipe Connections

    3.4.3 Recommended Pipe Connections proportional to temperature. Individual boiler firing is controlled by packaged boiler thermostats on boiler Installation of flexible connections in the flow and return outlets. heating pipework is recommended to ensure that stress is not transmitted from the pipework to the heat Maintain constant flow in the primary circuit at all times.

  • Page 27: Gas Fuel System

    3.5 Gas Fuel System High pressure, 6.5 barg, 650 kPa (94 psi) Low pressure, 4.8 barg, 480 kPa (70 psi) 3.5.1 Gas Supply System from Gas The maximum inlet pressure to the GBC must not Boost Compressor (GBC) exceed 700 mbarg, 70000 kPa (101526 psi). Pressure Range Gas Supply System The micro turbine requires gas be supplied at a pressure...

  • Page 28: Protection Against Reverse Pressurization In Gas Supply

    Vent Valve Filter 50 Micron Manual Block Valve Block Valve Inlet Valve FCZ 2 FCZ 1 Block Valve GVCPI Closed Position Indicator Pressure Customer Gauge Connection Terminals Low Gas Pressure High Gas Pressure Switch Switch Figure 3-9 Connection Diagram for Gas Safety Train 3.6 Protection Against Reverse temperature below the gas dewpoint.

  • Page 29: Cooling Air Intake And Outlet

    ° (1112 F) for the micro turbine simple cycle. Insulate the Exhaust Cooling Combustion Cooling exhaust duct and chimney to ensure a maximum Air Out Air Out Air In Air In ° ° surface temperature of approximately 55 C (131 The insulation will act as a thermal and acoustic barrier.

  • Page 30: Gas Safety Train Installation

    6. Remove protective caps from inlet and outlet water and to Section 5, Installation Drawings, for the gas connections and connect the water supply and safety train drawing. return pipes (see paragraphs 4 and 5). 3. All wiring to the gas safety train is by the installer. 7.

  • Page 31: External Controls, Remote Monitoring, And Metering

    Terminal Sizes 3.10.1 External Controls and Alarms Output isolator terminals: M12 bolts and nuts (supplied) For details of the terminal connections within the micro Main grounding terminal: M8 stud turbine for the following features, please refer to Customer connection sizes are onto terminal rail: Customer Connections Section 5,...
  • Page 32 turbine (RAC=1) and at, the same time, force RSS to micro turbine generating at nominally 80 kWe logic zero. After a short time (say 2 seconds), RAC goes continuously. If the heat demand is above 150 kWth, to logic zero at position 4 and a short time afterward at other boilers will have to be fired up.

  • Page 33: Remote Monitoring

    Remote Start/ Stop (RSS) Remote Alarm Clear (RAC) Delay = 15 minutes Figure 3-13 BMS Sequence During Routine Shutdown Anti-Hunting Control at Times of Low Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Thermal Demand Inspect the detectors per the manufacturer’s instructions.
  • Page 34 Notes Section 3 Installation Requirements TP-6242 8/03...
  • Page 35 The prestart checks. installer/contractor should complete the prestart checks and return it to Kohler Co., Warranty Dept. Upon receipt, Kohler Co. will contact the customer/contractor to arrange for a date for startup. Prestart Checklist...
  • Page 36 Notes Section 4 Prestart Checklist TP-6242 8/03...
  • Page 37 Section 5 Installation Drawings This section provides installation drawings. Title Page General Assembly & Installation Detail Micro Turbine Detail Customer Connections Without Dual Mode Switch Customer Connections With Dual Mode Switch Gas Safety Train, 24-Volt TP-6242 8/03 Section 5 Installation Drawings...
  • Page 38 9910-011 Section 5 Installation Drawings TP-6242 8/03...
  • Page 39 TP-6242 8/03 Section 5 Installation Drawings...
  • Page 40 9910-011 Section 5 Installation Drawings TP-6242 8/03...
  • Page 41 9910-011 TP-6242 8/03 Section 5 Installation Drawings...
  • Page 42 9910-011 Section 5 Installation Drawings TP-6242 8/03...
  • Page 43 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline fglass.
  • Page 44 kilo (1000) MTBF mean time between failure round head machine (screw) kelvin MTBO mean time between overhauls rly. relay kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory µF kg/cm kilograms per square microfarad rot.
  • Page 45 Appendix B Glossary of Micro Turbine Terms Unit of pressure (absolute) Barg Unit of pressure (relative) Building management system (Systems) combined heat and power, also known as cogeneration CHPQA Combined heat and power quality assurance C & M Control and monitoring Cogeneration (CG) Preferred name for combined heat and power systems Combustor...
  • Page 48 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6242 8/03 7 Jurong Pier Road Singapore 619159 E 2003 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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