DG Innovations in Engine-Based Systems: InVerde 100 kw System · InVerde 100 kw System. Tecogen...

Welcome to the Brooklyn, New York

Technology & Market Assessment ForumOctober 6-8, 2010 • New York Marriott® at the Brooklyn Bridge

Welcome to the Brooklyn, New York

Technology & Market Assessment ForumOctober 6-8, 2010 • New York Marriott® at the Brooklyn Bridge

DG Innovations in Engine-Based Systems:InVerde 100 kw System

10.7.2010Tecogen INV-100 Presentation at ESC Technology and Market Assessment Forum 166

Tecogen INV-100 Premium Power ModulePresentation at Technology and Market Assessment Forum – Brooklyn, NYOctober 7, 2010

Jeffrey Glick, Tecogen Inc.


Company Overview - Tecogen Businesses

• Products– Cogeneration and chiller

products– 1000’s installed– Waltham, MA factory

• Service– Contracts & parts support– Local service centers (7)– Tecogen products only


Tecogen Sales & Service

Service Centers

Chillers

Cogen Modules


Combined Heat & Power (aka cogeneration)

Definition: The simultaneous production of two useful outputs (electricity + heat) from a single fuel source

2-for-1: “A generator that makes free hot water”or

“A boiler that makes free electricity”

Gas in

1,263,000 Btu/hr

Electricity out

100 kW

Thermal out

700,000 Btu/hr

100.0%

27.0%

55.4%

>82.4% total (HHV basis)

>92.8% total (LHV basis)


System Concept/ BenefitsSystem Concept/ Benefits


Benefits to Site

• ECONOMICS– Cut energy costs by 30-50%– Qualify for incentives (utility/ fed/ state)– Reduce exposure to utility rate volatility

• ENVIRONMENTAL– Cut carbon footprint by 50%– Increase efficiency – Lower emissions

• SECURITY– Black-start capability (supplemental standby

capacity = “convenience power”)– Power quality– Reduce US dependence on foreign oil


Sample CHP Economics (3 INV-100’s, USA)

Value of Electricity Generated $ 378,000 /yearValue of Demand Savings (1 Unit – 100 kW) $ 28,800 /yearValue of Thermal Energy (Boiler Savings) $ 215,600 /year

REVENUES $ 622,400 /year

Cost of CHP Fuel $ 291,753 /yearCost of Maintenance Program $ 52,500 /year

COSTS $ 344,253 /year

NET ANNUAL OPERATING SAVINGS: $ 278,147 /year

INSTALLED COST: $ 1,200,000

SIMPLE PAYBACK: 4.3 years


EnvironmentalEnvironmental


Environmental Benefits of CHP: CO2 Emissions Reductions

CO2 emitted by utility power plant 1,390,667 lbs CO2/ yr = 695 tons CO2 per year

CO2 emitted by site's boiler 978,789 lbs CO2/ yr = 489 tons CO2 per year

TOTAL: 2,369,455 lbs CO2/ yr = 1,185

CO2 emitted by utility power plant 0 lbs CO2/ yr = 0 tons CO2 per year

CO2 emitted by site's boiler 0 lbs CO2/ yr = 0 tons CO2 per year

CO2 emitted by site's Tecogen unit(s) 1,216,800 lbs CO2/ yr = 608 tons CO2 per year

TOTAL 1,216,800 lbs CO2/ yr = 608

49% reduction

Tons CO2 per year

Tons CO2 per year

SITE'S GREEN HOUSE GAS EMISSIONS, WITH TECOGEN (CHP):

SITE'S GREEN HOUSE GAS EMISSIONS, WITHOUT TECOGEN (CONVENTIONAL)


Environmental Benefits of CHP: CO2 Emissions Reductions

GREENHOUSE GAS EMISSIONS FROM: 'SAMPLE TECOGEN INV-100

INSTALLATION'

695

489

608

0

200

400

600

800

1,000

1,200

1,400

without

TECOGEN

with TECOGEN

tons

CO

2/ y

ear by site's

Tecogenunit(s)

by site'sboiler

by utilitypowerplant

With TECOGEN INV-100, 576 fewer tons of

CO2 are emitted each year, by

'SAMPLE TECOGEN

INSTALLATION'

49% Reduction


FeaturesFeatures


CHP Products

• CM-60 & CM-75– Induction generator-based– Introduced 1983– Lower first cost– Excellent choice if standby

not required

• INV-100– Inverter-based– Streamlined interconnection– Latest product– Black-start capability– High part-load efficiency


Features (all models)

• Industrial Gas Engine– Proven Long-Life; Designed for Serviceability &

Lowest Lifecycle Costs– Lowest Emissions

• High-Efficiency• Engine Jacket, Oil, and Exhaust Gas Heat Recovery• Quiet Operation• Compact Design• State-of-the-Art “TecoNet” Microprocessor Controls

– “Open Protocol” (Modbus) & Remote Monitoring & Control System (RMCS) standard

• Electrical Switchgear– ETL-listed and compliant with UL1741 & Calif Rule

21 & NYSIR


INV-100 Features

• Qualifies for Standardized Interconnection– UL1741 Compliant– CE Marked for European Use

• Black-Start/Grid-Independent Operation– Compatible With CERTS

“Wireless Droop” Control• Power Quality

– No Reactive Power Use• Power Boost for Demand-Side

Response• Enhanced Efficiency• Low Emissions• Internationally Adaptable

– 50/60 hz


Shortcomings of the Tecogen Machine-Based Module

• No Black Start Capability – Inherent Conflict Between Safety and Synchronous Generators

• Interconnection Battle

– Control of Multiple Generators on Single Circuit • Too Complex/ Incomprehensible to Installing Engineers & Service Techs

• Growing Interconnection Demarcation – Machine Based Products vs. Inverters– Simplified Interconnection Becoming “Inverter-Only” Club

• Fuel Consumption Impaired by Fixed RPM Operation – Part Load Especially/ Also at Full Load (Power Reserve Margin)

• More Aggressive Rating (Higher RPM) Prohibited– Normal Operation– “Sprint” Feature for Demand Response


Premium Power Module - Inverter Interface

Natural Gas Engine

Amorphous Metal Generator

To Exhaust After Treatment & Heat Recovery

Variable Frequency

AC

Rectifier Inverter

High Quality 3-Phase,

50 or 60 Hz Power

DC

Optional DC Input from Auxiliary Device

(solar PV, Battery, Fuel Cell, etc.)

RPM Volts Freq (hz) KW1000 98 135 392200 207 297 933000 258 405 130

Engine/Generator Output

Power Conversion

Volts Freq (hz) KW480 60 37480 60 88480 60 123

Delivered kW


Development History

• Basic Product Funding For Module– 2003: Initial Funds by Tecogen– 2004: Research Contract Award

• California Energy Commission• Secondary Sponsor: Sempra Energy• Tecogen Cost Share

• Microgrid Development– Invited to Participate in Phase II of CERTS

Microgrid Program (2005)– CEC Sponsorship– Key Participants

• LBNL/ University of WI / American Electric Power (AEP)

– Demo of full-scale Microgrid • 3 Tecogen Modules/ Univ. of Wisconsin Software


CERTS Test Facility at AEP’s Dolan Lab Columbus OH

Three Tecogen Units


Commercial Design

• General Layout• Components• Performance• Microgrid Application


General Layout

• Additional Features– Water-cooled

Generator/ Electronics

– Large Oil Sump– New Exhaust HX/

Catalyst Design• Extra Cat Surface

– Extra Sound-Attenuated Enclosure

PCS&

Control

IC Engine

Exh. HR/Emissions

After-treatment

PMG


Power Electronics/ Generator


Performance

G e n . E ff.

E n g . E ff.

E n g . h p .

G e n k W

0

2 0

4 0

6 0

8 0

1 0 0

1 2 0

1 4 0

1 6 0

1 8 0

2 0 0

1 0 0 0 1 5 0 0 2 0 0 0 2 5 0 0 3 0 0 0

E n g in e -G e n e ra to r R P M

Hor

sepo

wer

or k

ilow

atts

0 %

2 0 %

4 0 %

6 0 %

8 0 %

1 0 0 %

Excellent part-load efficiency


CM-100 X

Typical Facility - Normal Operation

• Three Unit Site• All Feed Power Into The

Same Circuit– “Load Center”

• INV-100’s Provide Some Power– 3 x 100 kW (300 kW)

• Balance From the Utility• Example:

– Loads all 100 kW (500 kW Total)

– Utility Supplies 200 kW

• “X” Reactance – Key Device for Load

Sharing Controls

Facility Breaker

CM-100 X

CM-100 X

UtilityFeed

Load Group 1

Load Group 2

Load Group 3

Load Group 4

Load Group 5


CM-100 X

Typical Facility - Outage

• Facility Breaker is Open to Isolate System/Protect Linemen

• Excess Loads are Disconnected– load 2 and 4 in this

Example

• Units Power Loads 1, 3, 5• Power is Shared Equally• No Load Sharing Controls

Required• Can be Manual or

Automatic• Or “UnInterruptible” (UPS)

Facility Breaker

CM-100 X

CM-100 X

UtilityFeed

Load Group 1

Load Group 2

Load Group 3

Load Group 4

Load Group 5


a

b

c

e

d

Load Center 1 (LC-1)

m

Load 1

Load 2

Load 3

Load 4

Load 5

Transformer

Pre-installation One -Line


Several Options for Electrical Interface to CM-100

• Configuration A– Second Load Center for “Sensitive” Loads (Outage

Powered Loads)• Configuration B

– Rework Existing Load Center– Shunt Trip Coils For Isolation & Load Shedding– Can be Seamless with Synchronizer/ Addition Breaker

Operators• Configuration C

– Same as 2 except with Static Switch– Seamless but Costly

• Need to Understand Cost– Is One Approach Generally Less Expensive or Easier to

Implement?– Cost Model Possible?


a

b

c

e

d


m1

Load 1

Load 2

Load 3

Load 4

Load 5

Transformer

Contactor

Load Center 2 (new)

Shunt Trip CB

G1

G1

Basic Configuration “A”

m2


a

b

c

e

d


m1

Load 1

Load 2

Load 3

Load 4

Load 5

Transformer

Contactor

Load Center 2 (new)

Shunt Trip CB

G1

G1

Outage Step 1: Isolate Loads/ Isolate Generators

m2


a

b

c

e

d


m1

Load 1

Load 2

Load 3

Load 4

Load 5

Transformer

Contactor

Load Center 2 (new)

Shunt Trip CB

G1

G1

Outage Step 2: CERTS Operation/ Synch Generators

m2


a

b

c

e

d


m1

Load 1

Load 2

Load 3

Load 4

Load 5

Transformer

Contactor

Load Center 2 (new)

Shunt Trip CB

G1

G1

Outage Step 3: Close Contactor to Loads

m2


a

b

c

e

d


m1

Load 1

Load 2

Load 3

Load 4

Load 5

Transformer

Contactor

Load Center 2 (new)

Shunt Trip CB

G1

G1

Utility Restored: Isolate Gen/ Reconnect Loads

m2


Product Market Position

• Unique Capability– Small Scale DG Product– Built-in Black-start Capability

• UPS Quality

– No Specialized Installation Know-how Required -Even in Multiple Units

• Follow Textbook for Three-Phase Motor• Manage Sequence of Operation

• Competition– Conventional Engines: Requires Complex Controls– Microturbines: Requires Batteries/ Supervisory

Controls– Fuel Cells/Wind/Solar PV: Ditto


Production Rollout

• Shipped 10 units– Field Test unit - Claremont Club– 6 - Madison Oneida BOCES– 3 Jewish Home & Hospital– 1 Claremont CA Athletic Club


InVerde Installation List September 2010

• Madison Oneida BOCES (6)• Jewish Home & Hospital (3)• Claremont Club (1)• Indigo Hotel (1)• DuCool/ Roxann (1)• The Princeton Club of NY (3)• Mansfield Community Center (1)• Myrtle Avenue (Toren) (5)• Rancho San Antonio (1)• Saints Joachim & Anne (3)• Hydrochem Sp. Zo.o. (1)• Twin Marquis, Inc. (2)• Van Blarcom Closures (12)• Forest Hills Coop (1)• Linden Plaza (5)

• Phoenix Beverage Pier 7 (6)• 11 5th Avenue (4)• Ultra Flex Packaging (3)• Doral Arrowwood (3)• Americana Bayside (3)• The Harley School (1)• AEP/Lawrence Berkeley (1)• SMUD (3)• 70 Units Sold Since Rollout

– 31 Units Operating– 61 New York– 5 California– 1 Massachusetts– 1 Connecticut– 1 Ohio– 1 Warsaw, Poland


Madison-Oneida Vocational School, Verona NY

• Six Unit Site (600 kW)• NYSERDA Grant Recipient


Madison Oneida (Cont.)

• Traditional CHP Application– Space Heating (Winter)/ Heat Activated Cooling (Summer)

• Full 600 kW Operation in Outage– Utilizing CERTS “Wireless Droop


Installations

• Athletic Club, Claremont, CA– Recreational facility– 1 INV-100 & 3 CM-75’s– Appln: CHP & stand-by– Start-up: 2008– CEC Field Test

Olympic pool & spas Family pool & spa Laundry & DHW

thermal loads:


Installations

• Athletic Club, Claremont, CA

New INV-100 with 3 earlier units


Installations

• Hotel, Newton, MA– 8-story high-rise hotel– 1 INV-100– Appln: CHP stand-by– Start-up: 2008


Installations

• Hospital & Nursing Home, Bronx, NY– 7-story high rise– 3 INV-100’s– Appln: CHP & stand-by– Start-up: 2008


Installations

• Twin Marquis, Brooklyn, NY– Manufacturer of

assorted Asian food products

– 2 INV-100– Appln: CHP & stand-by– Start-up: 2010– Project partially

funded by National Grid and the Energy Solutions Center (ESC)


Installations

• Boys Home, Chatsworth, CA– Residential facility– 1 INV-100– Appln: CHP & stand-by– Start-up: Jan 2009


Installations

• Nursing Home & Rehab Center, Brooklyn, NY– 7-story high rise– 3 INV-100’s– Appln: CHP & stand-by– Start-up: early 2009


Installations

• Condominiums, Brooklyn, NY– 38-story high rise– 5 INV-100’s– Appln: CHP & stand-by– Start-up: early 2009


Installations

• Residence & Club, New York, NY– Residential & recreational

facility– 10-story high rise– 3 INV-100’s– Appln: CHP & stand-by– Start-up: early 2010


Where Tecogen and Gas Utilities Go From Here

• Future Projects Beyond 2010– Traditional Domestic Territories/ Close to Service Centers– Build-Up Local Population of units – To Open New Service Centers

• Joint Marketing– Tecogen to Assist Utilities with Joint Marketing Efforts– Tecogen Available for Presentations to Local Engineering Companies– Target Audience

• Engineers/End Users/ESCO’s– Tecogen’s Representative Network is Ready Move

• Demonstration and Coordination Projects with Utilities (Electric/Gas)– Product Awareness– Utilities Can Assist With the Deployment of the InVerde Product


Tecogen Contacts

• East Coast/ Midwest– Jeff Glick – 781-466-6481– [email protected]

• West Coast/ Southwest– Bill Martini– 503-641-1768– [email protected]

DG Innovations in Engine-Based Systems: InVerde 100 kw System · InVerde 100 kw System. Tecogen...

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