GAS GENERATOR SET FROM NATURAL GAS A TOGNUM GROUP BRAND

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Oliver Osborne
6 years ago
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1 GAS GENERATOR SET FROM NATURAL GAS A TOGNUM GROUP BRAND

2 YOUR REQUIREMENT IS OUR ASSIGNMENT: BETTER ENERGY FOR A BETTER FUTURE. MTU Onsite Energy is one of the core brands of Tognum AG, a world-leading provider of distributed energy systems, diesel engines, fuel injection systems and complete propulsion systems for ships, heavy-duty land and rail vehicles, military vehicles and the oil and gas industry. Under the umbrella of Tognum AG, MTU Onsite Energy bundles the competencies for distributed energy systems and offers you comprehensive, intelligent and innovative system solutions for diesel and gas technology for all applications, for the most diverse needs. Sustainability is one of MTU Onsite Energy s core values. Today and in the future, our focus is on developing and implementing system solutions for producing energy from climate-neutral, regenerative fuels such as combined heat and power plants (CHP) fueled by natural gas. The CHP systems of MTU Onsite Energy not only supply energy they provide better energy. Better energy In the future, natural gas will replace other fossil fuels to produce clean energy and to improve the global ecological balance. Natural gas fueled energy modules and generator sets from MTU Onsite Energy are technologically advanced solutions with outputs ranging from 100 kw el to 2.2 MW el that combine environmental sustainability with economic efficiency. 2 / // MTU Onsite Energy MTU Onsite Energy / // 3

COMBINING OUR ENERGIES TO MAKE ENERGY: ECONOMICAL, RELIABLE, SUSTAINABLE. MTU benefits from more than 100 years of experience in manufacturing engines.

All distributed gas power systems we design and realize benefit from this outstanding combination of know-how.

Whether for power generation alone, for cogeneration (CHP) or trigeneration (CHPC), whether for farmers, municipal authorities or the commercial sector: We develop systems solutions specifically

Our technology offers many advantages: // Economical Depending on the conditions, the use of these systems offers promising revenue potential.

3 COMBINING OUR ENERGIES TO MAKE ENERGY: ECONOMICAL, RELIABLE, SUSTAINABLE. MTU benefits from more than 100 years of experience in manufacturing engines. MTU Onsite Energy can rely on more than 35 years of expertise in development, design, manufacturing and support of complete systems. All distributed gas power systems we design and realize benefit from this outstanding combination of know-how. The use of biogas and sewage gas is one of the typical applications for MTU Onsite Energy CHP generators and modules based on gas engines. Whether for power generation alone, for cogeneration (CHP) or trigeneration (CHPC), whether for farmers, municipal authorities or the commercial sector: We develop systems solutions specifically configured for individual applications and customer requirements. Our technology offers many advantages: // Economical Depending on the conditions, the use of these systems offers promising revenue potential. Size and number of modules are defined by a profitability analysis for each specific application. The analysis also demonstrates the customer s profit potential when using an MTU Onsite Energy CHP system. // Environmentally friendly In accordance with energy policies, MTU Onsite Energy focuses on reducing the emissions of greenhouse gases. In comparison with conventional power generation, MTU Onsite Energy CHP modules provide a CO 2 reduction of up to 50 %. // Sustainable Combined heat and power (CHP) systems use a combustion engine to drive a power generator. Heat accrued during the combustion process is transferred via heat exchangers and provided to consumers. The high efficiency of CHP systems enables up to 40 % reduction in primary energy usage compared to conventional power systems. // Reliable Our gas power systems have proven their reliability, availability and longevity in many applications and over hundreds of thousands of operating hours. Our advanced control technology ensures a high availability rate for your system. Thanks to our extensive service network, you will receive speedy support from our experienced service partners anytime, anywhere. With our MTU ValueCare portfolio, we provide comprehensive service solutions which guarantee the efficiency of your system in the long term. // Independent An onsite distributed heat and energy supply saves energy, as it enables users to customize it to their needs and avoids transmission losses. In areas with missing or unreliable public infrastructure, MTU Onsite Energy systems ensure independent power and heat supply. 4 / // MTU Onsite Energy MTU Onsite Energy / // 5

CHP SYSTEMS: PROVEN THOUSANDFOLD. FOR A SECURE ENERGY SUPPLY. Today s energy production is mainly focused on fossil fuels.

environment necessitate the rethinking of energy practices.

gensets and modules can effectively explore this potential.

emissions. They are used in many different areas.

4 CHP SYSTEMS: PROVEN THOUSANDFOLD. FOR A SECURE ENERGY SUPPLY. Today s energy production is mainly focused on fossil fuels. However, the limited supply of these fuels as well as the negative impact that current technologies have on the environment necessitate the rethinking of energy practices. Gas powered energy systems offer great potential for playing an important role in the energy mix of the future and our gensets and modules can effectively explore this potential. By deploying our gas engines, power, heat and cooling energy based on natural gas can be generated economically, eco-friendly and reliably. Our natural gas powered modules and gensets are technologically mature solutions combining highest performance with low emissions. They are used in many different areas. Whether in the municipal or the commercial sector we develop perfectly customized solutions for each application. Common natural gas powered CHP applications are: // Housing estates // Hospitals // Swimming pools // Industry and commerce // Hotels // Schools // Public buildings // Telecommunication centers // Data centers // Leisure centers // Shopping centers // Greenhouses 6 / // MTU Onsite Energy MTU Onsite Energy / // 7

CHP SYSTEMS: HIGHLY VERSATILE. INDIVIDUALLY DIMENSIONED. Building maintenance Thanks to their reliability and efficiency, our CHP systems are often deployed in the field of local heat supply.

Local heat is an economically viable alternative to separate heat generation in the individual buildings. Its users benefit from various cost advantages.

Additionally, users gain space since a boiler plant in their own building is no longer necessary. The CHP covers the heat requirement base load economically, reliably and eco-friendly.

Industry Companies with a continuous demand for electricity and heat for their production processes can benefit from cogeneration systems.

5 CHP SYSTEMS: HIGHLY VERSATILE. INDIVIDUALLY DIMENSIONED. Building maintenance Thanks to their reliability and efficiency, our CHP systems are often deployed in the field of local heat supply. There are convincing arguments for the use of distributed energy supply systems powered by natural gas especially when it comes to the accommodation of numerous buildings and housing units. Local heat is an economically viable alternative to separate heat generation in the individual buildings. Its users benefit from various cost advantages. Besides the lower specific investment costs, maintenance is less complex and therefore more cost effective for one bigger system than for various small ones. Additionally, users gain space since a boiler plant in their own building is no longer necessary. The CHP covers the heat requirement base load economically, reliably and eco-friendly. Heat storage and an additional peak load boiler enable a flexible generation adaptation to the users heating profile. Industry Companies with a continuous demand for electricity and heat for their production processes can benefit from cogeneration systems. Whether in food processing, chemical production or traditional manufacturing processes, our CHP systems provide power, heat and cooling energy for the individual demands of industrial applications efficiently and independently. MTU Onsite Energy s gas powered CHP modules are also an interesting alternative if the capacities of production facilities are to be extended. Instead of increasing line capacities, you invest in a distributed, independent energy solution. In order to enhance their production processes profitability, more and more companies decide for our CHP systems. We will be happy to inform you about the possible savings potential within your energy supply on the basis of an economic efficiency calculation. Safety-critical applications For safety-critical applications, for example in hospitals or data centers, a continuous energy supply is essential. Our gas engine systems have proven themselves many times. Depending on the legal requirements on site, our CHP modules can also take on emergency power generator functions. 8 / // MTU Onsite Energy MTU Onsite Energy / // 9

ALL YOU NEED: POWER. POWER AND HEAT. POWER, HEAT AND COOLING ENERGY.

power and heat generation or even power, heat and cooling energy.

Power supply Our gas gensets are frequently used for simple power generation, guaranteeing a 24/7 security

According to the demands, our systems can be used for grid-parallel or off-grid operation.

Hospitals, schools, sports facilities, office and administrative buildings, department stores and shopping

Energy modules from MTU Onsite Energy can provide a significantly more economical alternative.

Whether in the chemical industry or metal processing, parallel power generation can increase the operating

Power, heat and cooling heat supply (CHPC) Using an absorption chiller, CHP systems can also create cooling

6 ALL YOU NEED: POWER. POWER AND HEAT. POWER, HEAT AND COOLING ENERGY. With our aggregates, modules and container solutions, we offer different systems to supply basic power, power and heat generation or even power, heat and cooling energy. Whatever application you focus on MTU Onsite Energy systems fulfi l your demands. Power supply Our gas gensets are frequently used for simple power generation, guaranteeing a 24/7 security of supply at locations with unreliable or missing electricity networks. According to the demands, our systems can be used for grid-parallel or off-grid operation. Power and heat supply (CHP) Many buildings and building complexes have a high demand for heat and power. Hospitals, schools, sports facilities, office and administrative buildings, department stores and shopping centers often separately generate heat and obtain power from the public grid. Energy modules from MTU Onsite Energy can provide a significantly more economical alternative. The heat generated by our CHP systems can be used not only for heating but also as process heat, e.g. in industrial enterprises. Whether in the chemical industry or metal processing, parallel power generation can increase the operating efficiency. Power, heat and cooling heat supply (CHPC) Using an absorption chiller, CHP systems can also create cooling energy with their generated heat - a flexibility that can, for example, enable the climate control for a whole office block. The additional costs for an absorber are low, and thanks to the longer lifespan, the system s operating efficiency can be further increased. The supply of cooling energy plays an important role not only for building climatization. It can be used in many other fields, such as process cooling for manufacturing, food refrigeration, ambient cooling in temperature sensitive areas (e.g. data centers) or building maintenance. Consequently, the generation of cooling energy extends the possibilities of using our CHP systems in a very cost effective way. We will gladly provide you with a cost-benefit-analysis for your individual application. 10 / // MTU Onsite Energy MTU Onsite Energy / // 11

GAS GENSETS AND CHP MODULES: PROVEN, EFFICIENT, RELIABLE. Gas gensets and modules from MTU Onsite Energy systems are technologically advanced solutions with a high degree of electrical efficiency.

// Our lean-burn engines prevent the production of harmful emissions in the actual combustion process itself.

// The MTU Onsite Energy oxygen-content control system guarantees optimum combustion even with variable gas qualities, preventing engine damage.

7 GAS GENSETS AND CHP MODULES: PROVEN, EFFICIENT, RELIABLE. Gas gensets and modules from MTU Onsite Energy systems are technologically advanced solutions with a high degree of electrical efficiency. They have proven their reliability, availability and longevity in many applications and hundreds of thousands of operating hours. // Our lean-burn engines prevent the production of harmful emissions in the actual combustion process itself. Emission levels below the limits required by the German TA Luft clean air regulations and similar standards in other countries are reliably achieved even without the use of a catalytic converter. // The MTU Onsite Energy oxygen-content control system guarantees optimum combustion even with variable gas qualities, preventing engine damage. // The arrangement of the cooling system enables straightforward integration into existing heating systems. // The exhaust heat exchanger is integrated into the engine coolant circulation system, minimizing the risk of heat exchanger damage. Our gas modules and gensets for natural gas cover the power range from 120 to 2,200 kw el. The selection of the right CHP system depends on various factors. We will provide you with wide-ranging support, all the way from the project idea to its realization. // Support in planning your new CHP module // Explanation of how to incorporate the CHP module into your application // Explanations of the technology behind the engine, system and individual components // Offer creation with budget price for planning phase and fi xed price for implementation // Design and planning of peripheral systems // Advice on service solutions as early as the project phase // Help with questions on legal situations (EEG, formaldehyde bonus) We will gladly provide you with more information by telephone or visit you for a personal meeting on site. // By the use of largely standardized and carefully selected subassemblies, maximum operational safety and reliability are achieved. Availability figures of well over 90% are the norm with MTU Onsite Energy systems. // Low fuel and lubricant consumption combined with long component life reduce operating costs. // A separate development department constantly analyzes the data from the use of our systems in the field and optimizes the technology on our test benches for a vast diversity of natural gas application requirements. 12 / // MTU Onsite Energy MTU Onsite Energy / // 13

8 COMPACT CHP SYSTEMS: REQUIRES MINIMUM SPACE. PROVIDES MAXIMUM EFFICIENCY. Series 400 Output range kwel MTU Onsite Energy has an advanced product program, with reliable gas engines at its heart. Many of our systems have already completed well over 100,000 hours of service and still continue to reliably supply heat and electricity day after day conclusive proof of the dependability of our engine technology. We generally design CHP modules as multi-module systems so that overall system outputs of as much as 5 MW el can be achieved with optimum efficiency. Adjustment to the electrical or thermal load profile is achieved by switching in or shutting down individual modules. Another advantage of multi-module systems is their high level of availability. Our compact module technology is based on the economical principle of optimizing both output and benefit. Over 2,500 CHP modules in use worldwide are proof of that. Compact modules not only offer high levels of electrical and thermal efficiency with a fuel-efficiency level of up to 90 % and beyond, but also many other benefits. MTU Onsite Energy s compact modules are: // Space-saving // Supplied ready to connect // Factory tested // Available as uncovered or enclosed units // Easy to maintain When planning distributed energy systems using CHP modules, the question of additional use as a grid backup or emergency power generator often arises. With synchronous generator and starter battery, our modules are fundamentally suitable for emergency power generation. All hard- and software adaptations necessary within the module control and monitoring will be carried out after technical clarification with the operator Description of individual components 1 Gas engine // Advanced and proven Series 400 gas engine, optimized for natural gas use. Combustion chambers ensure the highest level of efficiency in this performance category. 2 Generator // Optimally tailored to the engine and made by renowned manufacturers, the generator ensures a high level of reliability with the best degree of efficiency. 3 Ignition system // Ignition systems for individual cylinders allow for the most efficient level of operation for all cylinders, even with variable CH 4 content. The ignition voltage display gives customers information about the state of the spark plugs. 4 Mixture cooler // The two-stage mixture cooler with large surface area improves engine performance and heat utilization. 5 Knock detection // Cylinder-specific knock detection and regulation protects the engine from abnormal operating conditions and guarantees safe operation even with natural gas, which contains high levels of methane. 6 Crank-case ventilation // Improved crank-case ventilation minimizes deposits in intake tract and combustion chamber and guarantees a continuously high level of performance. 7 MTU Module Control (MMC) // The MTU Module Control (MMC) contains all the important functions necessary for controlling the system. All the auxiliary drives required for the CHP system can be operated from here. The integrated power circuitry minimizes the need for cabling on site. 14 / // MTU Onsite Energy MTU Onsite Energy / // 15

9 SPLIT-CONFIGURATION CHP SYSTEMS: GREAT PERFORMANCE. GREAT FLEXIBILITY. Series 4000 Output range 750 2,200 kwel Energy modules and generator sets for outputs up to 2,200 kw el per unit complete the MTU Onsite Energy range of natural gas CHP systems. Unlike the small series modules, these systems are supplied as split-configuration installations rather than as compact modules. This means that the engine-and-generator set and the heat module are made as separate units. With the sizes that are required for the high outputs involved, our split configuration offers greater benefits for the operator. Advantages of MTU Onsite Energy split-configuration modules: // Separation of the heat generation module // Individual modification to customers requirements // Optimal adaptation to the space available at the installation site // Optional warm-water generation with various temperature ranges as well as steam generation with separate waste heat utilization // Easily transportable // Simplified installation Like the compact modules, the engine-and-generator sets are comprehensively factory tested before delivery to the client Description of individual components 1 Gas engine // Advanced and proven Series 4000 gas engine, optimized for natural gas use. Combustion chambers ensure the highest level of efficiency in this performance category. 2 Generator // Optimally tailored to the engine and made by renowned manufacturers, the generator ensures a high level of reliability with the best degree of efficiency. 3 Ignition system // Ignition systems for individual cylinders allow for the most efficient level of operation for all cylinders, even with variable CH 4 content. The ignition voltage display gives customers information about the state of the spark plugs. 4 Mixture cooler // The two-stage mixture cooler with large surface area improves engine performance and heat utilization. 5 Knock detection // Cylinder-specific knock detection and regulation protects the engine from abnormal operating conditions and guarantees safe operation even with natural gas, which contains high levels of methane. 6 Crank-case ventilation // Improved crank-case ventilation minimizes deposits in intake tract and combustion chamber and guarantees a continuously high level of performance. MTU Module Control (MMC) // The MTU Module Control (MMC) contains all the important functions necessary for controlling the system. All the auxiliary drives required for the CHP system can be operated from here. The integrated power circuitry minimizes the need for cabling on site. The MMC is housed separately in the control cabinet and is therefore hidden from sight. 16 / // MTU Onsite Energy MTU Onsite Energy / // 17

CONTAINER UNITS: GENERATING ENERGY WHEREVER YOU WANT. As a system supplier, we offer a wide variety of solutions.

Compact, complete, flexible and autonomous, they are ideally suitable for mobile power generation or for applications that do not provide enough space for the insertion of a complete gas engine

When producing electricity from natural gas, installing the generator set in a container can be a useful alternative to the more common option of permanently installing a static system in a generator

The container includes: // The generator set // The switchgear including control and monitoring system // All necessary connection and supply systems (ventilation, lubricant supply, heat recovery,

10 CONTAINER UNITS: GENERATING ENERGY WHEREVER YOU WANT. As a system supplier, we offer a wide variety of solutions. In addition to our gas engine systems for use in buildings, we also provide containerized turnkey units. Compact, complete, flexible and autonomous, they are ideally suitable for mobile power generation or for applications that do not provide enough space for the insertion of a complete gas engine system. When producing electricity from natural gas, installing the generator set in a container can be a useful alternative to the more common option of permanently installing a static system in a generator room. Our standardized container genset is designed to meet the requirements of a variety of applications. The container includes: // The generator set // The switchgear including control and monitoring system // All necessary connection and supply systems (ventilation, lubricant supply, heat recovery, etc.) Like all MTU Onsite Energy systems, the standard container gensets are capable of fully automatic and continuous operation. The systems start up on their own whenever there is an adequate quantity of gas available with a minimum methane content, and shut down again automatically when the gas supply is insufficient. We offer two types of containers for different requirements: // Power Containers generate only electrical energy and are ideal for remote locations or areas with unreliable power supply. // Combined heat and power units (CHP) generate electrical and thermal energy, e.g. for operators whose processes require heat in addition to power. Your advantages: // Technically mature, proven and eco-friendly gas engine technology for maximum efficiency and reliability // Completely autonomous overall design that does not require any additional buildings // Flexible unit assembly system based on standardized modules and synchronized components // Readily available, compact turnkey plug & play solutions // Optimal support thanks to a worldwide service network // Quality certified under ISO 9001 and DIN EN ISO / // MTU Onsite Energy MTU Onsite Energy / // 19

MTU ONSITE ENERGY: ONE FOR ALL. CHP MODULE CONTROLLER: THE BRAINS OF THE SYSTEM. MTU Onsite Energy is your system partner.

Oxidation catalyst Tailored to the respective engine, the catalyst guarantees adherence to specific emissions standards.

extractor fan control, gas warning system, lubricant system, smoke detector and gas compressor. Gas safety plan MTU Onsite Energy has developed a comprehensive gas safety plan for entire systems.

11 MTU ONSITE ENERGY: ONE FOR ALL. CHP MODULE CONTROLLER: THE BRAINS OF THE SYSTEM. MTU Onsite Energy is your system partner. This means that as well as supplying the actual module or genset, we offer you a whole range of perfectly developed system components. Oxidation catalyst Tailored to the respective engine, the catalyst guarantees adherence to specific emissions standards. Auxiliary drive control and electrical connections The integrated MMC (MTU Module Control) offers a range of connections and control options, such as hot water pumps, mixed cooling water pumps, extractor fan control, gas warning system, lubricant system, smoke detector and gas compressor. Gas safety plan MTU Onsite Energy has developed a comprehensive gas safety plan for entire systems. The plan guarantees protection against internal and external explosions and has been tested by the TÜV. Talk to us our specialists will be happy to advise you. MTU Onsite Energy supplies you with the complete system engineering package for your installation. One of the most important aspects is the control system technology, which comes standard when you buy from us. If the generator set is the heart of the system, then the module controller is its brain. Our industrial-computer controlled and reliable electronics monitor the engine and the overall system to ensure optimum operation. The most important features are: // Control via RPS // Operation and visual display by means of industrial PC and touch-screen panel with colour display // Visual display of all functional processes and controls // Numerous additional controls and functions can be integrated (CH 4, gas tank, heat production mode, heat storage, mains power usage) // Networking of multi-module systems via Ethernet // Can be linked to master control systems // Wide choice of interface protocols (Ethernet, Profibus DP, 964R, Modbus RTU) // Logging of all fault and status messages in a database (up to six months of data can be recorded) // Optional remote diagnosis via ISDN // Optional integration of SMS / client (notification of faults, daily reporting of all meter readings) 20 / // MTU Onsite Energy MTU Onsite Energy / // 21

MTU VALUECARE: SUPERIOR SERVICE FOR LONG SYSTEM LIFE AND TOP PERFORMANCE.

The demands on complete systems for electricity and heat production are high. We are committed to offering the best services and maintenance solutions.

MTU ValueCare is perfectly developed for your cogeneration system, helping to maximize its availability and efficiency.

12 MTU VALUECARE: SUPERIOR SERVICE FOR LONG SYSTEM LIFE AND TOP PERFORMANCE. Purchasing a gas power system from MTU Onsite Energy pays off in many ways: not just by its performance and reliability, but also because of the security you get from our superior service. The demands on complete systems for electricity and heat production are high. We are committed to offering the best services and maintenance solutions. With that as our goal, we offer you a portfolio of services that goes above and beyond the technology itself MTU ValueCare. MTU ValueCare is perfectly developed for your cogeneration system, helping to maximize its availability and efficiency. The three main product lines of MTU ValueCare are: ValueService Our service program ValueService encompasses solutions for maintenance, training, documentation and repairs, which MTU Onsite Energy tailors specifically to your CHP systems and to meet your needs. // With our individually tailored service contracts, repair contracts, maintenance contracts and inspection contracts for any system, you can save costs over the whole life cycle of the unit, increase the availability rate and avoid individual repairs. // Our training courses for gas power systems are taught by highly-qualified and experienced instructors. Courses are conducted in our training centers or at your facility. MTU Onsite Energy training programs make operating staff proficient with MTU Onsite Energy engines and systems. // With our diagnostic solution, Remote Services, you ll have direct access to the activity of your cogeneration systems no matter where you are. You can receive predefined operational reports by or SMS to ensure that you are always well informed. Remote Services also provides the ideal basis for operational decisions and guarantees optimal utilization. ValueSpares Our genuine MTU spare parts and top-quality consumables are perfectly tailored to your CHP system and ensure the continued peak performance of your MTU Onsite Energy cogeneration systems. ValueExchange Our ValueExchange program incorporates a basic overhaul of the engine as well as the refurbishment of components and parts. Remanufactured engines and parts have the same appearance, the same life expectancy and the same performance as new products. Most also enjoy warranties similar or identical to their new counterparts. Our ValueExchange program is a costeffective alternative to new engines and parts. 22 / // MTU Onsite Energy MTU Onsite Energy / // 23

13 /12 VMC B Printed on chlorine-free paper. Subject to alteration due to technological advances. MTU Onsite Energy GmbH Gas Power Systems / Dasinger Strasse 11 / Augsburg / Germany / Phone +49 (821) / Fax +49 (821) / info-oeg@mtu-online.com A TOGNUM GROUP COMPANY

COMBINED HEAT AND POWER FROM NATURAL GAS. Valid for North America

COMBINED HEAT AND POWER FROM NATURAL GAS Valid for North America CONTENTS 04 MTU Onsite Energy 06 Overview of gas engine systems 08 CHP systems: advantages 10 CHP systems: applications 12 Compact CHP systems: