FOR THE PURECELL 400 FUEL CELL IN WILLIMANTIC, CT. Draft. June 22, Submitted to:

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1 MONITORING PLAN FOR THE PURECELL 400 FUEL CELL AT EASTERN CONNECTICUT STATE UNIVERSITY IN WILLIMANTIC, CT Draft June 22, 2012 Submtted to: Unted Technologes Power 195 Governor s Hwy South Wndsor, CT Submtted by: CDH Energy Corp. PO Box Bngley Rd. Cazenova, NY (315)

3 TABLE OF CONTENTS Introducton... 1 System Descrpton... 1 Heat Recovery Montorng System... 1 Calculated Quanttes... 6 Project Web Ste... 8 Appendx A Montorng System Detals

Introducton Ths plan descrbes our approach to montorng the performance of the fuel cell systems nstalled at Eastern Connectcut State Unversty (ECSU) n Wllmantc, CT.

4 Introducton Ths plan descrbes our approach to montorng the performance of the fuel cell systems nstalled at Eastern Connectcut State Unversty (ECSU) n Wllmantc, CT. The UTC Power PureCell Model 400 fuel cell provdes clean and effcent electrc power and thermal output to the faclty. Ths fuel cell s expected to supply electrcty n addton to standby power n the event of a power grd falure. The faclty wll also recover heat from the fuel cells to use for space and Domestc Hot Water (DHW) heatng. System Descrpton The PureCell Model 400 unt s nstalled on the campus besde the Scence Bldg. The fuel cell (FC) has separate electrcal feeds for parallel operaton wth the utlty or to provde backup power when solated from the grd. The fuel cell s able to provde 400 kw of electrcal power and up to 1.7 mllon Btu/h of heat. If fully utlzed, the fuel cell can obtan a thermal effcency near 90%. Power Output: 400 kw 480V, 3ph Heat Output: 1.55 MMBtu/h (low temp) 0.59 MMBtu/h (hgh temp) Fgure 1. PureCell 400 Unt Most of the thermal output from the FC s used to provde space condtonng and water heatng for the faclty. The low temperature loop supples 130 F water to meet Domestc Hot Water (DHW) loads (see Fgure 3). The hgh temperature loop supples 180 F water to meet space heatng and other buldng loads. Heat Recovery Montorng System The heat recovery montorng system (HRM) has been desgned to capture the electrcal and thermal performance of the system. Table 1 summarzes the measurements that wll be captured at the ste. CDH Energy 1 June 2012

5 Fgure 3 shows where the measurements wll be made n the thermal loops. Flow and temperature sensors are nstalled for three thermal loops: low temperature, hgh temperature, and coolng water. Data are extracted from the Power Plant Controller (PPC) va MODBUS TCP. The Obvus AcquSute datalogger logs the requred data. Table 1. Summary of Measured and Collected Data at the Ste Channel / Source Data Pt Descrpton Instrument / Meter Sgnal / Regster Eng Unts Wre Notes Man-1 TLS Low Temp Supply Temp (from FC) 10k Thermstor, Type 2 ohm F TLS Man-2 TLR Low Temp Return Temp (to FC) 10k Thermstor, Type 2 ohm F TLR Man-3 THS Hgh Temp Supply Temp (from FC) 10k Thermstor, Type 2 ohm F THS Man-4 THR Hgh Temp Return Temp (to FC) 10k Thermstor, Type 2 ohm F THR Man-5 TCWS Coolng Module Supply Temp (from FC) 10k Thermstor, Type 2 ohm F TCWS Man-6 TCWR Coolng Module Return Temp (to FC) 10k Thermstor, Type 2 ohm F TCWR EXP-1 FL Low Temp Water Flow Oncon F ma gpm FL 3" Sch 40 Steel, 100 gpm EXP-2 FH Hgh Temp Water Flow Oncon F ma gpm FH 3" Sch 40 Steel, 70 gpm EXP-3 FCW Coolng Module Flow Oncon F ma gpm FCW 2" Type L Copper, 60 gpm Modbus TCP FG Instantaneous Fuel Flow PPC 7173 kg/h Float page 12 of FCFR Modbus TCP FGcum Cumulatve Fuel Consumpton PPC 7191 m³ Float page 12 of FCFR Modbus TCP WFC Instantaneous Power Output PPC kw Float page 12 of FCFR Modbus TCP WFCcum Cumulatve Power Produced PPC 7217 MWh Float page 12 of FCFR Modbus TCP EFF_ELEC Instantaneous electrcal effcency (LHV) PPC 7505 % Float page 12 of FCFR Modbus TCP FC_STATE Fuel Cell Mode/State Number PPC 5 Number Unsgned Int page 12 of FCFR Modbus TCP RTIME Cumulatve "Load" Tme PPC 7205 hrs Float page 12 of FCFR Modbus TCP NALARM Total number of alarms PPC 21 Number Unsgned Int page 12 of FCFR Modbus TCP FC_ISTATE Fuel Cell Inverter State Number PPC 13 Number Unsgned Int page 12 of FCFR Modbus TCP SWV Make-up water tank fll valve status PPC 763 On/Off Boolean/Int page 12 of FCFR Modbus TCP SGI Grd ndependent status PPC 60 On/Off Boolean/Int page 12 of FCFR Modbus TCP SGC Grd connect status PPC 59 On/Off Boolean/Int page 12 of FCFR Note: EXP = Obvus expanson board, devce 003 Man = Obvus man board, devce 250 Low Temp Loop Hgh Temp Loop Coolng Water Loop TLS TLR THS THR FL Fuel Cell FH TCWR Coolng Module TCWS FCW Fgure 3. Schematc of Heat Transfer Loops n Fuel Cell System CDH Energy 2 June 2012

6 HRM / Fuel Cell FL FH TLR Fgure 4. Locatons of Heatng Loop Flow Sensors CDH Energy 3 June 2012

7 THS THR TLS TLR HRM / Fuel Cell Fgure 5. Locatons of Heatng Loop Temperature Sensors CDH Energy 4 June 2012

8 TCWR TCWS FCW Fgure 6. Locatons of Coolng Module Temperature and Flow Sensors The montorng system s based around the Obvus AcquSute data logger. The layout of the HRM and the connectons wth other network components of the Fuel Cell system are shown n Fgure 7. A Babel Buster gateway devce reads MODBUS data from the PPC and makes that data avalable to the Obvus data logger. CDH Energy 5 June 2012

9 Analog nputs Thermstors 4-20 ma HRM Box Ethernet Swtch RMS Box / Fuel Cell Ethernet Swtch AcquSute MODBUS TCP Dg to Internet Babel Buster MODBUS TCP MODBUS TCP PPC MODBUS TCP RMS Fgure 7. Layout of HRM, RMS and PPC Network Calculated Quanttes Heat Recovery Rates The data to determne the delvered heat recovery energy and the delvered coolng wll be collected by the datalogger at each scan nterval and then averaged for each 15-mnute recordng nterval. The calculatons lsted below wll be completed before the data are dsplayed on the web ste: Q lo 1 n n 1 k lo FL ( TLS TLR ) Q h 1 n n 1 k h FH ( THS THR ) Q cw 1 n n 1 k cw FCW ( TCWS TCWR ) CDH Energy 6 June 2012

10 where: Q xx - Delvered heat recovery for loop xx (Btu/h) (xx :: lo = low temp, h = hgh temp, cw = coolng water) k xx - densty specfc heat product constant for flud n loop xx - th scan (or read) n - number of scans n the averagng perod The loop flud s expected to be water wth propylene glycol (e.g., DowFrost). The factor k s equal to: Low Temp Loop: k lo = Btu/h gpm F for glycol at 130 F Hgh Temp Loop: k h = Btu/h gpm F for glycol at 180 F Coolng Water Loop: k cw = Btu/h gpm F for glycol at 150 F Assumng all loops use 40% glycol. The Useful and Unused heat recoveres wll be: Q useful = Q lo + Q h Q unused = Q cw Power and Energy Generally power meters can provde a host of data ponts, many of them redundant. Our approach, where possble, s to grab the regster value assocated wth energy (kwh) and from that value determne the average power for each 15-mnute nterval. Ths average power value s defned as: kw avg kwh t Ths average Power over a short tme nterval (15 mnutes) s usually ndstngushable from the demand or nstantaneous power data reported by most meters (most utltes use a sldng 15- mnute nterval). The fuel cell PPC s gven as nstantaneous kw. Cumulatve reads are n kwh. Effcency Calculatons The electrcal and total effcency of the Fuel Cell, based on the lower heatng value of the fuel, wll be calculated usng: electrcal LHV WFC FG CDH Energy 7 June 2012

11 total WFC LHV ( QL 1 QH ) FG 3600 where: QL, QH - Useful heat recovery low, hgh temperature loops (Btu/h) WFC - Power output (kw) FG - Generator gas nput (kg/h) LHV - Lower heatng value for natural gas (~48,667 kj/kg) Project Web Ste CDH wll create a web ste for ECSU that provdes access to all the hstorc data collected at the ste. The webste wll provde custom, detaled plots and tables of the collected data from the ste that wll be updated once a day. CDH Energy 8 June 2012

12 Appendx A - Fuel Cell HRM at ECSU Internet address: Table 1. Summary of Major HRM Components Obvus AcquSute A8812 Control Solutons Babel Buster BB Ths datalogger ncludes thermstors and flow meters to measure thermal loads. It also reads MODBUS regsters from the Babel Buster. All data are stored n the AcquSute memory and transferred to the CDH Energy servers from ths devce. Ths gateway devce reads data from the PPC (va MODBUS TCP) and makes t avalable as MODBUS data to the AcquSute. Table 2. Summary of Data Sensors Power Plant Controller PPC Oncon F-1111 Flow Meter Oncon F-1211 Flow Meter Vers TIG seres Thermstor Ths fuel cell controller provdes data as MODBUS regsters to the Babel Buster. Ths hgh accuracy, nserton-style, mpeller flow meter measures water flow through each of the heat loops and provdes a 4-20mA sgnal to the AcquSute. Lke the Oncon F-1111, ths s a hghly accurate, nserton-style, mpeller flow meter. The F-1211 s desgned to handle a shorter straght length of ppe. Ths 10kΩ Type 2 Thermstor reacts to temperatures n the heat loops. The resultng resstances are measured and stored by the AcquSute. ECSU System Detals 1 June 22, 2012

13 Analog nputs Thermstors 4-20 ma HRM Box Ethernet Swtch RMS Box / Fuel Cell Ethernet Swtch AcquSute MODBUS TCP Dg to Internet Babel Buster MODBUS TCP MODBUS TCP PPC MODBUS TCP RMS Fgure 1. Layout of HRM and RMS Network The Babel Buster provdes all the communcatons (.e., reads) between the devces on the network. It reads data from the PPC devce and makes the data avalable for the Obvus AcquSute datalogger to read. The AcquSute logs all the data. Table 3. Network Devces and Addresses Network Layout IP Address Label Devce Protocol AcquSute Obvus AcquSute Modbus TCP Babel Buster CSI Babel Buster 2 Mult-network Interface Modbus TCP BACnet PPC UTC Power Power Plant Controller (PPC) Modbus TCP ECSU System Detals 2 June 22, 2012

14 Babel Buster Varable Table 4. Lstng of Data Ponts Collected from all Devces Source CDH Name UTC / Obvus Varable Name Descrpton Natve Unts Babel Buster MODBUS Address Source Data Address Source Data Type Notes Babel Buster Data Type Eng Unts AI-1 PPC FG FUEL Fuel flow rate kg/h Float Float kg/h AI-2 PPC FGcum CUMFUEL Cumulatve fuel consumed at standard temperature m³ Float Float m³ AI-3 PPC WFC KW Electrcal power output kw Float Float kw AI-4 PPC WFCcum MWH Cumulatve electrcal power output MWh Float Float MWh BI-1 PPC SWV WTRVLV Make-up water tank fll valve status On/Off Boolean/Int Boolean On/Off AI-5 PPC EFF_ELEC EFFELEC Instantaneous electrcal effcency % Float Float % AI-6 PPC FC_STATE STATE Fuel cell state Number Number 11 5 Unsgned Int Float Number BI-2 PPC SGI GISTATUS Grd ndependent status On/Off Boolean/Int Boolean On/Off BI-3 PPC SGC CGSTATUS Grd connect status On/Off Boolean/Int Boolean On/Off AI-7 PPC RTIME LOAD Cumulatve load tme hr hrs Float Float hrs AI-8 PPC NALARM NUMALARMS Total number of alarms Number Unsgned Int Float Number AI-12 PPC FC_ISTATE ISTATE Inverter State Number Number Unsgned Int Float Number Man-1 TLS TEMPLGOUT Temperature low grade heat supply F 39 ohm 10k, Type 2 Float Ohms Man-2 TLR TEMPLGIN Temperature low grade heat return F 41 ohm 10k, Type 2 Float Ohms Man-3 THS TEMPHGOUT Temperature hgh grade heat supply F 43 ohm 10k, Type 2 Float Ohms Man-4 THR TEMPHGIN Temperature hgh grade heat return F 45 ohm 10k, Type 2 Float Ohms Man-5 TCWS TEMPCWOUT Temperature coolng module supply F 47 ohm 10k, Type 2 Float Ohms Man-6 TCWR TEMPCWIN Temperature coolng module return F 49 ohm 10k, Type 2 Float Ohms EXP-1 FL FLOWLG Flow rate low grade heat gpm ma (0-150) Oncon F-1211 Float ma x 1000 EXP-2 FH FLOWHG Flow rate hgh grade heat gpm ma (0-100) Oncon F-1211 Float ma x 1000 EXP-3 FCW FLOWCW Flow rate coolng module gpm ma (0-150) Oncon F-1111 Float ma x 1000 = Data provded or receved from PPC va MODBUS TCP = Data from sensors on Obvus AcquSute ECSU System Detals 3 June 22, 2012

15 Babel Buster XML Fle <?xml verson="1.0" encodng="iso "?>  <confguraton> <bacnet_objects> <obj d="1" name="fuel" unts="95"/> <obj d="2" name="cumfuel" unts="95"/> <obj d="3" name="kw" unts="95"/> <obj d="4" name="mwh" unts="95"/> <obj d="5" name="effelec" unts="95"/> <obj d="6" name="state" unts="95"/> <obj d="7" name="load" unts="95"/> <obj d="8" name="numalarms" unts="95"/> <obj d="12" name="istate" unts="95"/> <obj d="13" name="serial" unts="95"/> <obj d="3001" name="wtrvlv" unts="95"/> <obj d="3002" name="gistatus" unts="95"/> <obj d="3003" name="cgstatus" unts="95"/> <obj d="20" name="acqusute TLS" unts="95"/> <obj d="21" name="acqusute TLR" unts="95"/> <obj d="22" name="acqusute THS" unts="95"/> <obj d="23" name="acqusute THR" unts="95"/> <obj d="26" name="acqusute TCWS" unts="95"/> <obj d="27" name="acqusute TCWR" unts="95"/> <obj d="28" name="acqusute FL" unts="95"/> <obj d="29" name="acqusute FH" unts="95"/> <obj d="31" name="acqusute FCW" unts="95"/> </bacnet_objects> <modbus_devces> <dev d="1" paddr=" " unt="1" rate=" " name="utc PPC" swapped="1"/> <dev d="2" paddr=" " unt="250" rate=" " name="acqusute Man Board"/> <dev d="3" paddr=" " unt="3" rate=" " name="acqusute Exp Board"/> </modbus_devces> <clent_read> <rule localreg="1" remtype="hold_reg" remreg="7173" remfmt="float" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="fuel"/> <rule localreg="2" remtype="hold_reg" remreg="7191" remfmt="float" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="cumfuel"/> <rule localreg="3" remtype="hold_reg" remreg="10535" remfmt="float" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="kw"/> <rule localreg="4" remtype="hold_reg" remreg="7217" remfmt="float" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="mwh"/> <rule localreg="5" remtype="hold_reg" remreg="7505" remfmt="float" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="effelec"/> <rule localreg="6" remtype="hold_reg" remreg="5" remfmt="unt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="state"/> <rule localreg="7" remtype="hold_reg" remreg="7205" remfmt="float" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="load"/> <rule localreg="8" remtype="hold_reg" remreg="21" remfmt="unt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="numalarms"/> <rule localreg="12" remtype="hold_reg" remreg="13" remfmt="unt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="istate"/> <rule localreg="13" remtype="hold_reg" remreg="20" remfmt="unt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="serial"/> <rule localreg="3001" remtype="col" remreg="763" remfmt="nt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="wtrvlv"/> <rule localreg="3002" remtype="col" remreg="60" remfmt="nt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="gistatus"/> <rule localreg="3003" remtype="col" remreg="59" remfmt="nt" dev="1" scale=" " offset=" " poll="1.00" bpunts="96" name="cgstatus"/> <rule localreg="20" remtype="hold_reg" remreg="1" remfmt="double" dev="2" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute TLS"/> <rule localreg="21" remtype="hold_reg" remreg="3" remfmt="double" dev="2" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute TLR"/> <rule localreg="22" remtype="hold_reg" remreg="5" remfmt="double" dev="2" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute THS"/> <rule localreg="23" remtype="hold_reg" remreg="7" remfmt="double" dev="2" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute THR"/> <rule localreg="26" remtype="hold_reg" remreg="9" remfmt="double" dev="2" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute TCWS"/> <rule localreg="27" remtype="hold_reg" remreg="11" remfmt="double" dev="2" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute TCWR"/> <rule localreg="28" remtype="hold_reg" remreg="1" remfmt="double" dev="3" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute FL"/> <rule localreg="29" remtype="hold_reg" remreg="3" remfmt="double" dev="3" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute FH"/> <rule localreg="31" remtype="hold_reg" remreg="5" remfmt="double" dev="3" scale=" " offset=" " poll="1.00" bpunts="96" name="acqusute FCW"/> </clent_read> <rtu_devce> <dev baud="9600" party="2stop" slave="1" unt="10"/> </rtu_devce> </confguraton> ECSU System Detals 4 June 22, 2012

16 Table 5. Sensor and Wrng Detals for AcquSute Channel / Source Data Pt Descrpton Instrument / Meter Sgnal / Regster Eng Unts Wre Notes Man-1 TLS Low Temp Supply Temp (from FC) 10k Thermstor, Type 2 ohm F TLS Man-2 TLR Low Temp Return Temp (to FC) 10k Thermstor, Type 2 ohm F TLR Man-3 THS Hgh Temp Supply Temp (from FC) 10k Thermstor, Type 2 ohm F THS Man-4 THR Hgh Temp Return Temp (to FC) 10k Thermstor, Type 2 ohm F THR Man-5 TCWS Coolng Module Supply Temp (from FC) 10k Thermstor, Type 2 ohm F TCWS Man-6 TCWR Coolng Module Return Temp (to FC) 10k Thermstor, Type 2 ohm F TCWR EXP-1 FL Low Temp Water Flow Oncon F ma gpm FL 3" Sch 40 Steel, 100 gpm EXP-2 FH Hgh Temp Water Flow Oncon F ma gpm FH 3" Sch 40 Steel, 70 gpm EXP-3 FCW Coolng Module Flow Oncon F ma gpm FCW 2" Type L Copper, 60 gpm Modbus TCP FG Instantaneous Fuel Flow PPC 7173 kg/h Float page 12 of FCFR Modbus TCP FGcum Cumulatve Fuel Consumpton PPC 7191 m³ Float page 12 of FCFR Modbus TCP WFC Instantaneous Power Output PPC kw Float page 12 of FCFR Modbus TCP WFCcum Cumulatve Power Produced PPC 7217 MWh Float page 12 of FCFR Modbus TCP EFF_ELEC Instantaneous electrcal effcency (LHV) PPC 7505 % Float page 12 of FCFR Modbus TCP FC_STATE Fuel Cell Mode/State Number PPC 5 Number Unsgned Int page 12 of FCFR Modbus TCP RTIME Cumulatve "Load" Tme PPC 7205 hrs Float page 12 of FCFR Modbus TCP NALARM Total number of alarms PPC 21 Number Unsgned Int page 12 of FCFR Modbus TCP FC_ISTATE Fuel Cell Inverter State Number PPC 13 Number Unsgned Int page 12 of FCFR Modbus TCP SWV Make-up water tank fll valve status PPC 763 On/Off Boolean/Int page 12 of FCFR Modbus TCP SGI Grd ndependent status PPC 60 On/Off Boolean/Int page 12 of FCFR Modbus TCP SGC Grd connect status PPC 59 On/Off Boolean/Int page 12 of FCFR Table 6. Forwarded Addresses on Dg Modem ECSU System Detals 5 June 22, 2012

17 Obvus AcquSute The AcquSute data logger produces a separate fle of 1-mnute data for each devce. The read map for the data logger s gven below. Chan Name Devce Column FG, mb-001, 0 FGCUM, mb-001, 1 WFC, mb-001, 2 WFCCUM, mb-001, 3 SWV, mb-001, 4 EFF_ELEC, mb-001, 5 FC_STATE, mb-001, 6 SGI, mb-001, 7 SGC, mb-001, 8 RTIME, mb-001, 9 NALARM, mb-001, 10 ISTATE, mb-001, 16 FL, mb-003, 1 FH, mb-003, 6 FCW, mb-003, 11 TLS, mb-250, 1 TLR, mb-250, 6 THS, mb-250, 11 THR, mb-250, 16 TCWS, mb-250, 21 TCWR, mb-250, 26 Notes: mb-001 MODBUS Reads mb AcquSute Expanson Board mb-250 AcquSute Man Board Sensor Calbratons: Thermstor # Name Wre Input Channel Mult Offset TLS TLS Man TLR TLR Man THS THS Man THR THR Man TCWS TCWS Man TCWR TCWR Man ECSU System Detals 6 June 22, 2012

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