STRATOS MGM 160

biogas
TYPE SPECIFICATION OF COGENERATION UNIT

COGENERATION
GAS ENGINES

technical parameters
fuel  cogeneration unit  engine  heat balance  generator  cooling
flow diagram  dimensions  construction design requirements
Scope of supply

Standard scope

gas engine
- air filter
- gas mixer
- throttle valve
- ignition system
- starting batteries
synchronous generator
- automatic cosφ control
- automatic voltage control
heat recovery system
- plate heat exchanger
- exhaust gas boiler
- cooling water pump
- heating water pump
- three way valve with servo drive – temperature heating water regulation
- safety valve – heating water circuit
- safety valve – cooling water circuit
- expansion tank – cooling water circuit
gas train
- gas filter
- solenoid valve
- zero pressure regulator
- pressure switch for gas – high/low pressure indication
exhaust system
- exhaust gas silencer
- compensator
electrical switchboard
- control and power part (control system, circuit breaker, power switches and measuring units)
- modular control system
- power part (circuit breaker, power switches)

Options

back-up cooling system

- dry cooler – emergency cooling
- three way valve – control engine water temperature
oil equipment
- central lube oil tank
- oil level regulator
anti – noise protection
- anti – noise cover with electrical ventilation
- speed control of ventilation
engine
- preheater of the engine
Technical parameters

Fuel – gas quality on the inlet of gas engine

caloric fuel value of the biogas 23 MJ/m3

sulphane H2S concentration < 0,1% volumetric
chlorine concentration compounds < 100 mg/Nm3CH4
fluorine concentration compounds < 50 mg/Nm3CH4
total fluorine + chlorine concentration compounds < 100 mg/Nm3CH4
silicone – Si concentration < 5 mg/Nm3CH4
ammonia – NH3 concentration < 50 mg/Nm3CH4
oil vapor concentration < 250 mg/Nm3CH4
particle solid size < 5.10-6 m
fuel relative humidity < 60 %
fuel temperature 10 – 30 oC

Cogeneration unit

type of cogeneration unit STRATOS MGM 160

nominal electrical power output 160 kW
nominal heating power output 228 kW
nominal voltage 400/230 V
frequency 50 Hz
nominal power factor 1,0
operating power factor 0,8 – 1,0
operating pressure of gas on the inlet gas train 2-5 kPa
temperature gradient of heating system 90/70oC
water flow of secondary circuit 2,75 l/s
weight of cogeneration unit without anti – noise cover 2500 kg
weight of cogeneration unit with anti – noise cover 3400 kg
dimensions (length x with x height)
transportation 3676 x 1500 x 2300 mm
assembly with anti – noise cover 3676 x 1500 x 2800 mm
exhaust temperature behind exhaust boiler 125-185 C
capacity of central oil tank (option) 250 l
the engine comply with TA Luft 86 limits
noise pressure level of unit at distance 1m (without anti-noise cover) 97 +- 3 dB/A/
noise pressure level of unit at distance 1m (with anti-noise cover) 75 +- 3 dB/A/
exhaust noise pressure level at distance 5 m from outlet 73 +- 3 dB/A/
total recommended air exchange 11 200 m3/h
self power load consumption:
installed power load 6,1 kW
average operating power load (without emergency cooling): 3,4 kW
Engine

engine type MAN E 2876 LE302

nominal speed 1500 min-1
number of cylinder 6
bore 128 mm
stroke 166 mm
displacement 12,82 dm3 (l)
air ratio / combustion 1,6/lean burn
oil recommended (natural gas) Mobil Pegasus 705
oil recommended (biogas) Mobil Pegasus 610
lube oil filling quantity min. 30 l, max. 41 l
max. lube oil consumption 0,6-0,8 g/kWh
compression ratio 11:1
ignition point 12
engine weight (dry) 990 kg

Balance

% Load 100,0% 75,0% 50,0%

Fuel input [kW] 455 340 252
Mechanical power [kW] 168 126 84
Spec. fuel consumption[MJ/kWh] 9,7 9,7 10,8
Fuel consumption BIO [m3/h] 71,3 53,2 39,4
Alternator efficiency 94,8% 95,2% 94,8%
Electrical power output [kW] 160 120 80
Total heating power [kW] 229 163 126
Heat from jacket water [kW] 120 82 73
Heat from intercooler [kW] 19 12 5
Heat from exhaust [kW] 91 69 48
Elektrical efficiency 35,0% 35,3% 31,7%
Heating efficiency 50,3% 47,8% 50,0%
Total efficiency 85,3% 83,1% 81,7%
Combustion air [kg/h] 728 546 364
Exhaust temperature [°C] 528 531 537
Exhaust gas flow [kg/h] 793 595 408
Heat losses [kW] 32 24 18

¹related to 130 °C
gas caloric value 23 [MJ/m3]
performance data based on
ISO 3046/1 (+5%)
standard reference conditions:
pressure 100 kPa, temperature 25°C a relative humidity 30%.
tolerance for heating outputs data +-8%
Generator

synchronous alternator STAMFORD UCI 274 H1

nominal apparent power 200 kVA
nominal active power 160 kW
nominal voltage 400/231 VAC, 50 Hz
harmonic distortion (no load/ linear balanced load) <1.8% / < 5%
dir. axis transient (X′d) 16 %
dir. axis subtransient (X“d) 11 %
quad. axis subtransient (X“q) 15 %
transient time constant (T′d) 42 ms
sub-transtime constant (T“d) 12 ms
generator weight 629 kg
bearing number 1

Control system

Features
The modular system enables optimal configuration for each cogeneration unit. Control system consists
of central processor unit with application software, binary input / output modules, analog input / output
modules and mains protection (decoupling) relay. Graphical LCD is used to provide information of unit
state. Membrane keyboard and selector switches are used to set parameters. The control system
ensures fully automatic operation. Switchboard contains power part (circuit breaker fuse disconnectors,
contactors, relays) and control part. Switchboard cubicle is integrated to the unit frame.

Displayed values are sorted in the following groups

- actual values
- limit values
- control values
- status messages
- fault signal coding
- active alarm

Standard function
- unit automatic start / stop
- speed / power control
- automatic generator synchronization to grid in parallel mode
- mains failure detection (voltage, frequency, vector jump)
- reverse power protection
- process media temperature and pressure measurement (gas, water, oil)
- automatic sensor failure detection
- gas leakage detection
- communication interface signals (5 x DO, 2 x DI, 1 x AI, 1 x AO)
- operator warning before limit values reaching
- automatic stop after limit values exceeding

Options
- TELECONTROL system - complete remote service system including monitoring and remote control
on-line via Internet (using any kind of internet access – fix line, telephone line or GSM cell grid).
Direct help from MOTORGAS service center.
- island operation mode - supply of energy during blackout
- serial communication with user control system (Modbus, Profibus)
Emergency cooler

Drycooler GFH 067B/2-L(D)-F6/4P

Capacity 230.0 kW Medium ethylene glycol 34 %(1)

Air flow 17700 m³/h Pressure drop 0.42 bar
Capacity Volume flow 24.48 m³/h

Fans 2 Kusy 3~400V 50Hz Noise pressure level 55 dB(A)(2)

Data per motor At a distance of 5.0 m
Speed 870 min-1
Capacity 0.76 kW
Current 1.50 A

Tube volume 37 l Connections per unit

Weight (dry) 209 kg Inlet 76.1 * 2.00 mm
Outlet 76.1 * 2.00 mm
Dimensions
R L S B

L = 2250 mm
B = 1145 mm
H = 950 mm
R = 110 mm

H
L1 = 2175 mm

H1
0 13
H1 = 400 mm
S = 50 mm 37.5 20
L1
40
Flow diagram of cogeneration unit
STRATOS MGM 160
Cogeneration unit STRATOS MGM 160
without anti – noise cover

Legend:
1 - heating water circuit inlet flange DN 50, PN 6 (return water)
2 - heating water circuit outlet flange DN 50, PN 6
3 - emergency cooling outlet flange (to drycooler)
DN50,PN6
4 - emergency cooling inlet flange (from drycooler)
DN50,PN6
5 - exhaust outlet flange DN150, PN6
6 - gas inlet flange DN50, PN6
Cogeneration unit STRATOS MGM 160
with anti – noise cover

Legend:
1 - heating water circuit inlet flange DN 50, PN 6 (return water)
2 - heating water circuit outlet flange DN 50, PN 6
3 - emergency cooling outlet flange (to dry cooler)
DN50,PN6
4 - emergency cooling inlet flange (from dry cooler)
DN50,PN6
5 - exhaust outlet flange DN150, PN6
6 - gas inlet flange DN50, PN6
Construction requirements for engine rooms of cogeneration unit

Setting of cogeneration unit

- minimal free space from unit base frame on side of the unit 1200 mm (for both side)
- minimal free space in front of electrical switchboard 1200 mm
- minimal free space from side where piping connection 1000 mm

Minimal dimension of the inlet opening (doors) for moving in: width 1900 mm a height 2300
mm.

Engine and generator are coupled and mounted on steel base frame with inserted
antivibration elements. Transmission of the vibration is minimal. Normally there is no need to
prepare antivibration concrete blocks. It is sufficient to calculate the floor as for static weight
loading capacity
Ground plan dimensions for weight loading are 3000 x 1500 mm.
Requirement for engine room floor: dust free concrete or pavement

Ventilation of engine room

Engine room should be ventilated naturally or by ventilators with minimum three times per
hour air change rate. Minimal air change quantity technically required corresponds to the
heat lost from cogeneration unit and inlet air to be burned by engine – see technical
parameters chapter. Other safety requirements for air change will be solved according to
locally valid safety rules and standards.
To avoid freezing problems and because of better starting conditions it is recommended to
keep inside temperature in the engine room not lower than 5°C.

Oil equipment
Oil tank is option. It is located on base frame beside electrical switchboard.

Setting electrical switchboard

On the base frame

Setting of emergency dry cooler

outside
a) placed on concrete foundation
b) placed on bracket mounted on building

Venting (degassing)
piping above the roof with min. distance 3 m from possible source of the fire.
Exhaust piping
a) independent exhaust piping DN100 leaded over engine room
piping is made of stainless steel DIN 1.4301
b) leaded into chimney – overpressure system required

Heating customer system (secondary circuit)

Cogeneration unit is equipped:
Secondary circuit water pump included covering internal pressure drop
three way valve – control heating water temperature
safety valves on primary and secondary circuits
It is absolutely necessary to keep water flow through customer heating circuit when
engine is in operation. Danger of exhaust boiler damage.

Electrical equipment and power supply system

Earthing of the object with earth resistance less then 5 Ω must be supplied to the switchboard.
Generator will be fix grounded according to standard ČSN 33 2000-4-41 article 413.1.
Arrange power outlet 3f+N+PE/16A close to the unit.

Other requirements and space demand

I shape profile for crane crab – maximal load 1,6 t
Inlet gully for drainage from the exhaust
Fresh water including the washbasin in the engine room