Noblehurst Dairy Linwood, NY

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Abraham Stevenson
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1 Data Integrator Initial Data Summary Site Description This site is a dairy farm located in the Central New York town of Linwood. A 13 kw Caterpillar engine generator uses digester gas to produce electricity and useful heat recovery. The heat recovered from the engine is used to heat the digester and for auxiliary heating. The digester breaks down farm waste (mainly manure) and, instead of traditional waste removal, produces a combustible gas for the farm to use. Digester gas that cannot be utilized by the engine is burnt in a flare. Data for this site is collected by Connected Energy and provided to CDH Energy. Data Description Connected Energy provides the data for Noblehurst Dairy Farm via comma-separated variable (CSV) files uploaded once a day. The data set consists of 92 channels. CDH assigns engineering units based on the Connected Energy data system or makes assumptions based on previous experience. The set shown in Figure 1 describes the electrical generation for the engine generators powered by natural gas and biogas. Figure 1. Screen Capture of Connected Energy Webpage CDH Energy Corp. 1 October 27

2 DG/CHP Integrated Data System Channels Table 1 shows the processed data channels from rawdata used in the DG/CHP Integrated Data System for this facility. Table 1. Data Integrator Database Mapping Integrated Data System Channel DG/CHP Generator Output DG/CHP Generator Output Demand DG/CHP Generator Gas Input Units of Measure kwh/int Raw Data Column Descriptions [col] 1 Generator Real Power [BW] Raw Data Units kwh kw Generator Real Power [BW] cuft/int Total Cogen Gas Flow [I] Grid Energy to Farm [AL], kwh/int Total Facility Purchased Grid Energy from Energy Farm [AM] Grid Power to Farm [AN], kw Total Facility Purchased Grid Power from Demand Farm [AO] Other Facility Gas Use 2 cuft/int N/A N/A Total Facility Energy kwh/int Calculated kwh/h Total Facility Demand kw Calculated kw Utilized Heat Recovery Rate [Y] Calculation Formula = [BW ] * (15 minutes/int 6 minutes/hour) kw = [BW ] cuft = [I] kwh = [ AL AM ] kw = [ AN AO] = [Y ] * Useful Heat Recovery MBtu/int MBtu/h (15 minutes/int 6 minutes/hour) Dump Cooler Heat = [V ]* MBtu/int MBtu/h Unused Heat Recovery Rate [V] (15 minutes/int 6 minutes/hour) Status/Runtime of DG/CHP Generator Hours/int Calculated Ambient Temperature F Ambient Temp [Q] F = [Q] Total CHP Efficiency % LHV Calculated N/A Electrical Efficiency % LHV Calculated N/A 1 The Raw Data Column Description is from the Connected Energy CSV files. The corresponding column id (i.e., A, B, C ) is in square brackets and used for in the calculation formula. 2 There is no information for these data channels available from Connected Energy data. int - interval CDH Energy Corp. 2 October 27

3 Data Verification Calculated Value Corroboration Table 2 shows the calculations of heating loads for the various channels for which corroborating data was identified. For the corroborating heat flow calculations we used a factor of.5 MBtuh/gpm-F, which corresponds to pure water. For this table, calculations within 1% of the data reported by CE are marked as passing the check. Table 2. Checks on Heating Load Calculations Column Label [col] 1,2 Corroborating Columns [col] 1,2 Corroborating Formula Heat to Digester End Loop Discharge Temp [AY], Rate [AB] End Loop after Digest Temp [BA], ([ AY] BA])*[ L]*.5 (Cogen Side) Cogen Loop Flow [L] Heat to Digester Rate [AB] (Digester Side) Heat to Htg Aux Rate [AD] Dump Cooler Heat Dump Rate [V] Cogen Heat Recovery Rate [U] Cogen Heat Recovery Rate [U] Cogen % of Farm Bldg Power [AH] 4 (in kw) Cogen % of Farm Bldg Power [AH] 4 (in kwh) Total Farm Power [P] Cogen Total Elect Effic. [AG] 3,4 Site Total CHP Efficiency [AF] 3,4 Hot Water to Digester Temp [R], Hot Water from Digester Temp [S], Hot Water to Digester Flow [N] End Loop after Digest Temp [BA], End Loop after Ht Aux Temp [BB], Cogen Loop Flow [L] End Loop after Ht Aux Temp [BB], End Loop Return Temp [AZ], Cogen Loop Flow [L] End Loop Discharge Temp [AY], End Loop Return Temp [AZ], Cogen Loop Flow [L] Passed Check = No = ([ R] S])*[ N]*.5 = ([ BA] BB])*[ L]*.5 No = ([ BB] AZ])*[ L]*.5 = ([ AY] AZ])*[ L]*.5 Total Bio Gas Flow [F], Generator Real Power [BW] < ([ F]*6*.6) ([ BW]*3.413) No Generator Real Power [BW], Grid Power to Farm Cumul [AN], [ BW ] Grid Power from farm [AO} [ BW ] + [ AN] AO] Generator Real Power [BW], Grid Energy to Farm Cumul [AL], [ BW ]/ int Grid Energy from farm [AM} [ BW ]/ int+ [ AL] AM ] No Generator Real Power [BW], Grid Power to Farm [AN], = [ BW ] + [ AN] AO] Grid Power from Farm [AO] Generator Real Power [BW], [ BW ] / int* Total Bio Gas Flow Cumul [I] = [ I ]*.6 Generator Real Power [BW], Utilized Heat Recovery Rate [Y], Total Bio Gas Flow Cumul [I] ([ BW ] / int* 3.413) + [ Y ] / int = [ I ]*.6 1 The Raw Data Column Description is from the Connected Energy CSV files. The corresponding column id (i.e., A, B, C ) is in square brackets and used for in the calculation formula. 2 The column names beyond IV cannot be seen on any version prior to Microsoft Excel 27 due to program limitations. 3 A Lower Heating Value (LHV) for biogas of.6 Mbtu/scf was assumed for Bio Gas in these calculations. 4 int = interval = 15 minutes 6 minutes/hour. CDH Energy Corp. 3 October 27

4 In Table 2 rows in red show efficiency channels where the efficiency could not be compared to calculations from the database. The best-guess formula for the calculation is still listed in the table. The Site Electrical Efficiency and the Site Total CHP Efficiency could not be verified and is discussed in further detail in the following section. From the corroborating formula we see that the electrical efficiency data channel does pass the check as shown in Table 2. But we also notice that for a certain time period the electrical efficiency of the engine is very high. In order to narrow done the cause we have a time series plot as shown in Figure 2. From this plot we see that the marked area shows very low gas usage compared to the power output, which is the reason for a high electrical efficiency. Generator Gas Input (cfm) Generator Gas Data Q4 Q1 Q2 Q3 Q4 Q1 Q Generator Power Output (kw) Generator Power Output Q4 Q1 Q2 Q3 Q4 Q1 Q Electrical Efficiency (% LHV) Calculated Electrical Efficiency Q4 Q1 Q2 Q3 Q4 Q1 Q Figure 2. Time Series Comparison for Electrical Efficiency CDH Energy Corp. 4 October 27

5 Other Data Questions Heat To Digester Rate (Cogen Side) The Connected Energy data channel for Heat Recovery to the Digester does not match the calculated heat recovery as shown in Figure 3. The same heat recovery data channel does match the heat recovery calculated on the digester side as shown in Figure 4. 1 Comparison of Heat to Digester Rate (Cogen Side) 8 Calculated Data Channel (MBtu) Connected Energy Data Channel(MBtu) Figure 3. Comparison of Heat to Digester Rate at Cogen Side 5 Comparison of Heat to Digester Rate (Digester Side) 4 Calculated Data Channel (MBtu) Connected Energy Data Channel(MBtu) Figure 4. Comparison of Heat to Digester Rate at Digester Side CDH Energy Corp. 5 October 27

6 Heat to Htg Aux Rate The Connected Energy data channel Heat to Htg Aux Rate does not match the calculated heat recovery. Figure 5 shows the two temperatures in the corroborating calculation from Table 2. The loop temperature after the auxiliary heat heat exchanger is greater than the temperature after the digester, indicating a negative heat recovery value. 21 Heating Aux Heat Exchanger Temperatures Eng Loop after Digest Temp Eng Loop after Ht Aux Temp 2 Temperature (F) Q4 Q1 Q2 Q3 Q4 Q1 Q Figure 5.. Time Series Plot of Auxiliary Heat Heat Exchanger Cogen Temperatures CDH Energy Corp. 6 October 27

7 Cogen % of Farm Bldg Power From the data points in the raw data file, we understand that the Cogen % of Farm Bldg Power is the ratio of the Generator Real Power to the sum of the Generator Real Power and the difference between the Grid Power to Farm and Grid Power from Farm. The Grid Power to Farm and the Grid Power from Farm data is available in kw and kwh. The corroborating formulas for both kw and kwh are shown in Table 2. The graphical output for the same is shown in Figure 6 and Figure 7. From both the figures we see that the power in kw corroborates but the power in kwh does not corroborate. 15 Farm Building Power Comparison in kw Calculated Cogen % of Farm Bldg Power (%) Connected Energy Cogen % of Farm Bldg Power (%) Figure 6. Farm Building Power Comparison in kw 4 Farm Building Power Comparison in kwh Calculated Cogen % of Farm Bldg Power (%) Connected Energy Cogen % of Farm Bldg Power (%) Figure 7. Farm Building Power Comparison in kwh CDH Energy Corp. 7 October 27

8 Assumptions Summary Questions Here is a summary of the questions from a review of the data set: 1. Why does the gas input in February and March, 27 seem low compared to the generator output? Should this data be masked from the DG/CHP Database with a relational check on the electrical efficiency? 2. Why does the Heat to Digester Rate match the calculated rate on the Digester side but not the Cogen side? 3. Are the Eng Loop after Digest Temp and Eng Loop after Ht Aux Temp reversed? 4. Why does the Cogen % of Farm Bldg Power match the calculated rate when compared in kw but not in kwh? Recommendations This site is included in DG/CHP Database, however there are minor questions with data integrity. If any of the Data Channel Summary Table 3. Summary of Data Channels From CE Connected Energy Data Channel Units Column Label Accumulator Min Max Avg Nat. Gas to Engine Flow cfm C No Nat. Gas to Engine Cumul cuft D BioGas to Flare Flow Rate cfm E No... Total BioGas Flow cfm F No BioGas #1 to Eng. Flow cfm G No BioGas #2 to Engine Flow cfm H No Total BioGas Flow Cumul cuft I. 2,89, BioGas #1 to Eng. Cumul cuft J. 264, BioGas #2 to Engine Bldg Cumul cuft K. 18,28, Cogen Loop Flow gpm L No Cogen Loop Flow Cumul gals M. 16, Hot Water to Digester Flow gpm N No Hot Water to Digester Cumul gals O. 12, Total Farm Power kw P No Ambient Temp F Q No Hot Water to Digester Temp F R No Hot Water from Digester Temp F S No Raw Manure Temp F T No Cogen Heat Recovery Rate MBtu U No. 2, CDH Energy Corp. 8 October 27

9 Connected Energy Data Channel Units Column Label Accumulator Min Max Avg Dump Cooler Heat Dump Rate MBtu V No. 1, Cogen Heat Recovery Rate (Kwe) kwe W No... Dump Cooler Heat Dump Rate (Kwe) kwe X No Utilized Heat Recovery Rate MBtu Y No. 2, Utilized Heat Recovery Rate (Kwe) kwe Z No Heat Utilization % AA No Heat to Digester Rate MBtu AB No Heat to Digester Rate (Kwe) kwe AC No Heat to Htg Aux Rate MBtu AD No Heat to Htg Aux Rate (Kwe) kwe AE No Total CHP Efficiency % AF No Cogen Unit Electrical Efficiency % AG No Cogen % of Farm Bldg Power % AH No Manure Pump Status - AI No Dig. Effluent Pump Status - AJ No... Separator Status - AK No Grid Energy to Farm Cumul kwh AL. 145, Grid Energy from Farm Cumul kwh AM. 143, Grid Power to Farm kw AN No Grid Power from Farm kw AO No Room LEL #1 - AP No Room LEL #2 - AQ No Power Contrl to Gov Output - AR No Engine Oil Pressure psi AS No Digester Pressure psi AT No Rad. Speed Control Output % AU No Heat Pump Spd Cntrl Output % AV No Control Panel Temperature F AW No Engine Top Tank Temp F AX No Eng Loop Discharge Temp F AY No Eng Loop Return Temp F AZ No Eng Loop after Digest Temp F BA No Eng Loop after Ht Aux Temp F BB No Digester #1 Temperature #1 F BC No Digester #2 Temperature #1 F BD No Power Level (Pct Max) % BE No Generator Voltage Ph. A V BF No Generator Voltage Ph. A-B V BG No Generator Voltage Ph. B V BH No Generator Voltage Ph. B-C V BI No Generator Voltage Ph. C V BJ No Generator Voltage Ph. C-A V BK No Utility Voltage Ph. A V BL No Utility Voltage Ph. A-B V BM No Utility Voltage Ph. B V BN No CDH Energy Corp. 9 October 27

10 Connected Energy Data Channel Units Column Label Accumulator Min Max Avg Utility Voltage Ph. B-C V BO No Utility Voltage Ph. C V BP No Utility Voltage Ph. C-A V BQ No Engine Battery Voltage V BR No Generator Current Ph. A Amps BS No Generator Current Ph. B Amps BT No Generator Current Ph. C Amps BU No Utility Current Ph. C Amps BV No Generator Real Power kw BW No Generator Real Power, Ph. A kw BX No Generator Real Power, Ph. B kw BY No Generator Real Power, Ph. C kw BZ No Generator Apparent Power kva CA No Generator App. Pwr, Ph. A kva CB No Generator App. Pwr, Ph. B kva CC No Generator App. Pwr, Ph. C kva CD No Generator Reactive Power kvar CE No Generator React. Pwr, Ph. A kvar CF No Generator React. Pwr, Ph. B kvar CG No Generator React. Pwr, Ph. C kvar CH No Generator Power Factor - CI No Generator Pwr Factor, Ph. A - CJ No Generator Pwr Factor, Ph. B - CK No Generator Pwr Factor, Ph. C - CL No Engine Speed rpm CM No. 1, , Generator Frequency hz CN No Utilitiy Frequency hz CO No Engine Number of Starts - CP No 1. 3,75. 2,363.9 CDH Energy Corp. 1 October 27

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