Technical Description of ECOMAX 33 Natural Gas CHP

TECHNICAL DESCRIPTION OF
ECOMAX® 33 NATURAL GAS

MODULAR OUTDOOR
SOLUTION FOR:
GA Pet Food Partners
Plocks Farm, UK.
Offer: 17-05-2018
Rev. 5
ECOMAX® 33 NATURAL GAS

This technical description describes the ECOMAX® 33 Natural gas cogeneration module
with an electrical power output of 3.352 kW, complete with balance of plant equipment
and auxiliary systems, outlined by the conditions in the Commercial Offer (included in this
document).
TECHNICAL SPECIFICATION 1
1 STANDARD REFERENCE CONDITIONS
Seismic area No
Design temperature + 25 °C
Design pressure 1 bar(a) / 100 a.s.l.
Relative humidity 30%
Maximum operating external temperature + 30 °C
Minimum operating external temperature - 10 °C
Exhaust stack height (measured from ground level) 10 m
2 PERFORMANCE
The engine is subject to derating depending on temperature according to the manufacturer’s
specifications:
Ecomax® 33 - Electrical output (at generator terminals) 3.352 kW
Total thermal output as saturated steam at 10 barg (184,1 °C) 1.133 kW
Steam flow 1.814 kg/h
Total thermal output as hot water at 90 °C 1.996 kW
Island mode operation Not included
Black start capability Not included
3 EXHAUST EMISSIONS
Atmospheric emissions of co-generator are:
NOx (reported at 5% O2) 450 mg/Nm³

CO (reported at 5% O2) 300 mg/Nm³
Atmospheric emissions of co-generator, with SCR, are:
NOx (reported at 5% O2) 75 mg/Nm³

CO (reported at 5% O2) 100 mg/Nm³
NH3 (reported at 5% O2) 5 mg/Nm³
2 TECHNICAL SPECIFICATION
4 ECOMAX® MODULE
EFFICIENCY AND RELIABILITY
In order to achieve the best possible return on investment, a cogeneration plant has to
reliably perform at maximum efficiency. While focusing on high quality and cost-effective
technologies, AB is able to offer project-specific innovative solutions to meet the
customer’s needs. The choices made during the design process are able to prevent
performance issues and reduce equipment downtime, therefore also reducing the need for
maintenance. AB applies this attention to technical detail to the entire CHP plant, including
the purpose-built enclosure, the manufacturing process, equipment and component
selection, and other plant design details. The end result is a state of the art cogeneration
plant that delivers maximum performance and reliability.
4.1 CARBON STEEL CASING

The cogeneration system is housed in purpose-built enclosures which are designed for outdoor
installation. The enclosures are made of carbon steel and equipped with a high strength frame to
support the generator set. Among the main construction characteristics are:
 walls and a roof made with externally galvanized corrugated metal layers;
 corner lifting points for crane use;
 doors throughout the plant to enable easy access for maintenance operations; and
 manufacturing according to a high precision AB engineering and production process.
4.2 NOISE INSULATION

Rock wool panels covered by perforated steel sheets form the walls and ceiling of the ECOMAX®
housing unit. This noise dampening insulation is specifically designed to achieve the required residual
noise level.
Residual noise level in free field without acoustic reflex (according to the
standard reference conditions) and with soundproofing barrier will respect the
values indicated on your document “Energy Centre. Guidance on Sound Emissions
and Insulation, 15th June 2018.
4.3 VENTILATION SYSTEM

The superior quality of ECOMAX® systems is also reflected in the ventilation system, which is
designed in order to ensure the performance of the engine and its continuous operation throughout
a wide range of ambient conditions.
4.3.1 Inlet air system, equipped with:

 galvanized steel, weatherproof louvres;
 replaceable air filters;
 sound insulating baffles;
 VFD controlled blade fans.
4.3.2 Outlet air systems, equipped with:

 galvanized steel, weatherproof louvres;
 modulating air dampers;
 sound insulating baffles;
4.4 PAINTWORK
The external paint guarantees a high standard of durability and resistance to extreme weather
conditions for the ECOMAX® module. The design has been laboratory tested and has proven to be
resistant to salt spray corrosion (ISO 7253) for a duration greater than 1,000 hours. The painting
process for external components includes the following:
 surface preparation and washing;

 a primer coating suitable for galvanized surfaces;
 a rustproof epoxy layer; and;
 a polyurethane enamel layer, RAL 7035.
Visible internal surfaces are painted with a primer layer and a polyurethane enamel layer on visible
parts, RAL color 7035.
4.5 MAIN THERMAL CIRUITS

To ensure the reliability and functionality of the thermal recovery and dissipation circuits, AB uses
carefully dimensioned, seamless steel piping. This applies to the following connecting piping:
 connecting piping on jacket water circuit up to the plate heat exchanger;

 connecting piping on exhaust gas heat exchanger recovery circuit up to decoupling plate heat
exchanger;
 connecting piping on recovery circuit up to edge package flanges;
 connecting piping on jacket water circuit up to its own emergency dry cooler;
 connecting piping on after cooler circuit up to its own emergency dry cooler;
4.6 PLATE HEAT EXCHANGER ON HT RECOVERY CIRCUIT

A decoupling plate heat exchanger is placed on the module’s HT hot water recovery circuit. The
technical characteristics are to be decided during the executive design.
4.7 PLATE HEAT EXCHANGER ON LT RECOVERY CIRCUIT

A decoupling plate heat exchanger is placed on the module’s LT hot water recovery circuit. The
technical characteristics are to be decided during the executive design.
4.8 LUBE OIL SYSTEM

To ensure the continuity of service, the ECOMAX® module is equipped with a lube oil system
composed of two storage tanks, one for fresh and one for used oil. Each tank has a capacity of 1.000
litres and is equipped with pumps, valves, and pipes connecting to the engine.
4.9 COMPONENT DOCKING
In order to ensure a robust and long-lasting assembly, all components placed on the roof of the
ECOMAX® are held in place by galvanized steel support structures. These supports are prefabricated
at the AB factory.
4.10 EXHAUST GAS PIPING

The ECOMAX® is supplied with piping to connect the engine to the installed exhaust system
components. This exhaust gas piping is sized to accommodate the exhaust gas flow rate and pressure
losses. Expansion joints which are necessary to absorb thermal expansion caused by high
temperatures, or other factors, are included. A sampling point and condensate drain system are also
provided. The exhaust gas piping terminates at the exhaust stack, with an outlet height as indicated
in the exhaust parameters (section 3).
4.11 EXHAUST GAS SILENCERS

To reduce the acoustic emissions of the engine, are supplied and installed on exhaust gas circuit,
three top-quality exhaust gas silencers (two built on horizontal configuration and the other one in
vertical configuration), made of stainless steel welded cylinders and shell, designed to comply with
the required residual noise level.
PRACTICALITY AND SAFETY
The ECOMAX® product line has taken engineered CHP systems to the next level. It reduces
the footprint needed while housing all internal components in a manner which facilitates
maintenance activities thanks to amply dimensioned doors placed on the enclosure. AB
has given special attention to safety and security as well; each ECOMAX® contains proven
and reliable devices and systems that guarantee safe operation in all working conditions.
4.12 MODULE-INTEGRATED SAFETY

The enclosure’s constructive characteristics include a series of solutions to protect the plant’s
personnel. These features include a galvanized steel railing along the perimeter of the roof, a caged
ladder for roof access, and a floor designed to hold accidental oil spillage.
4.13 SMOKE AND GAS DETECTION SYSTEM

The module is equipped with smoke and gas detectors, installed inside the ECOMAX® module. The
system consists spot-type smoke sensors, one gas sensor inside the engine room near the gas train,
and an electronic detection and alarm unit. The smoke and gas detection system is only for engine
use.
4.14 EMERGENCY DRY COOLER

An emergency dry cooler will be installed on the roof of the unit. The exact technical specifications
of this component will be determined during the executive design phase to ensure optimal
performance.
4.15 ANTI-EXPLOSION SERVO ACTUATED VALVE

To ensure maximum security, AB provides an automatic detection valve on the gas train, certified
according to ATEX regulations.
CONTROL AND MANAGEMENT
To ensure complete, precise, and continuous management and control of the plant and all
its performance parameters, AB Engineering has designed an integrated system, which
can be used remotely, that allows for the monitoring of elements essential to operations.
All components on the command and control system are directly installed by AB
technicians and are part of the commitment to quality which distinguishes ECOMAX®
systems from the rest of the market. The control panels, placed in a specially designed,
air-conditioned room inside the module, provide a responsive and user-friendly interface
for the service staff.
4.16 UNIT CONTROL PANEL

The automatic auxiliary control system, developed by AB, manages the ECOMAX® unit’s basic
functions and its interface with the main power grid. The system acquires all analogue and digital
signals coming from the engine and is responsible for the control and management of the plant
auxiliaries. Signals relating to the principal safety systems are controlled by hardwired logic.
The system acquires measurements from the ECOMAX® unit directly. The main parameters which
are made available and processed by our monitoring system are the following:
 generator circuit breaker status;

 engine cooling water temperature and pressure;
 lube oil temperature and pressure;
 exhaust gas average temperature inside cylinders;
 return water temperature;
 exhaust gas temperature from each cylinder;
 number of starts;
 mixture intercooler temperature;
 engine and generator rpm;
 generator power factor;
 generator frequency;
 avarge generator current;
 average generator line voltage and line to neutral voltage;
 active, reactive and apparent generator power;
The above parameters will be processed, recorded, and displayed by the monitoring system. Through
the monitoring PC, it will be possible to set operating parameters and to acquire data to be displayed.
The panel will be equipped with variable speed drive units to control the fans for both the ventilation
and the dry coolers. The system will also be fitted with electronic synchronization equipment, in order
to automatically enter parallel operation with the electrical grid.
A G59 grid protection relay will be provided.
4.17 SCADA SUPERVISION SYSTEM
The architecture in the automation system found in the ECOMAX® has been designed to ensure the
integration of components and the security of performance. During the development of the SCADA
system, it has been a fundamental consideration to provide the following:
 easy control and adjustment operations;

 clear and simple reading of alarms;
 separation of circuit equipment and different systems to prevent operating and/or reading
errors; and
 easy interventions for maintenance and component replacement.
The electric network monitoring system will also perform the following functions:
 local and remote command management;

 functional calculations;
 regulation of operational parameters;
 electrical network monitoring; and
 automatic diagnosis of system data.
4.17.1 Supervision
The plant supervision system is based on the Siemens WinCC SCADA software, a platform with which
AB Impianti has extensive experience in automation applications. This choice is derived from the
adoption of Windows as the standard for automation systems and the need to use a Windows
compatible platform; it has enabled AB to provide effective technical support, both on-site and
remotely.
The design of the automation system monitoring the ECOMAX® ensures that all components are
integrated and safely operating in unison. The supervision system is designed considering the
following fundamental functions:
 display of plant performance;

 execution of operator commands;
 clear and simple reading of alarms; and
 display of data trends.
The software system will provide all functions in a simple and continuous format for the operator.
The software has been designed in a way to guarantee a high level of reliability and availability. The
system is flexible to allow for expansions and future updates. It is possible to connect to the system
through the internet for remote monitoring, using security provided by a firewall.
4.17.2 Graphics Pages

Care is given to the design of the graphics pages so that data and information is presented in a clear
and logical manner to the operator. Each page will consist of a graphical window showing a P&ID or
single line diagram to represent the specific mechanical or electrical system. An overview page is
included to provide a summary of the entire cogeneration system. Each metric will have a historical
graph which will allow for the review of past and present performance. The detailed pages for each
subsystem will display metrics for individual pieces of equipment, including the desired setpoint, the
actual operating point, and any present alarm or shutdown conditions. An alarm log will be available
to give a visual record of past alarm and shutdown conditions with a date and time stamp. Alarm
and shutdown conditions will be prominently displayed and will remain active until acknowledged by
the operator.
4.17.3 PROFINET/Profibus network

The Profinet network will connect control systems, group management, the auxiliary PLC, and other
necessary components using the Profibus protocol. The communications system will allow net
information checks where alteration to information in transit should be avoided.
4.18 OPERATION AND MAINTENANCE MANUAL
The operation and maintenance manual is intended to provide guidelines for basic maintenance
procedures for the ECOMAX®. The manual is divided into chapters, each having a different topic. It
gives information on the operation and maintenance of the product over the lifetime of the system,
while considering the following:
 the proper application of standards, and

 efficacy in communicating content according to the need, the sector of operation, and
operator qualification.
5 ECOMAX® ACCESSORIES
ENVIRONMENTALLY FRIENDLY TECHNOLOGY
Cogeneration is globally recognized as an application that can contribute significantly to
reducing emissions into the atmosphere through energy efficiency and a reduction in
overall energy consumption. AB‘s attention to this aspect has always been a driving factor
in its mission and it is what its plant design, scrupulously oriented towards maximizing
energy efficiency and minimizing emissions, is derived from. When it comes to pollution
reduction, ECOMAX® systems make use of a range of technologies to meet relevant
regulations.
5.1 EXHAUST GAS CLEANING SYSTEM (SCR).

In order to reduce CO and NOx emissions to the required levels, a urea-based exhaust gas treatment
system is included. The system uses a closed loop to control the dosage of urea which is injected
directly into the exhaust gas. Here it is mixed by static mixers which are installed inside the pipe.
The mixture then goes through the reduction section where the NOx reduction reaction occurs on
the porous surface of a catalyst, leading to the formation of water and nitrogen.
Downstream of the reduction section, an oxidation catalyst with a ceramic honeycomb matrix is
installed. This section ensures that the quantity of carbon monoxide, unburned hydrocarbons (non-
methane, non-ethane VOCs), and ammonia are reduced to the necessary levels.
A urea storage system is provided in a special enclosure, complete with two (2) tanks with a capacity
of 2000 liters each, a pump, and connecting piping.
System operation is guaranteed for 16000 working hours or 24 months from the first ignition,
whichever comes first.
THERMAL EFFICIENCY TECHNOLOGIES
5.2 EXHAUST HEAT RECOVERY UNIT FOR STEAM PRODUCTION
The exhaust heat recovery unit for the production of saturated steam consists of a horizontally
oriented heat exchanger with external insulation, and is designed with the following characteristics:
 annealed tubesheets, submitted to normalisation heat treatment;

 large diameter, carbon steel fire-tubes secured to the tubesheet by expansion with no need
for a welding belt;
 plates reinforcement through ribbing;
 double jacketed feedwater pipe;
 exhaust gas inlet and outlet chambers made from Cor-Ten A steel, compete with doors for
maintenance operations;
 valves (2nd safety valve included);
 control and regulation accessories;
 water level control panel;
 IP65 electric control panel;
 feedwater pump complete with necessary valves and filters;
 standby feedwater pump;
 continuous conductivity control system;
 pressure release valve;
 automatic blow-down system;
 economizer; and
 second stage economizer.
5.3 EXHAUST GAS CIRCUIT WITH BY-PASS

Properly sized exhaust gas piping connects the engine to the exhaust heat recovery unit. A bypass
circuit is included, made from AISI 304 stainless steel piping and equipped with a 3-way servo valve.
Flexible bellows are included as needed.
5.4 CONDENSARET DRAINAGE.

We provide a condensate drain from the exhaust gases pipeline, by welded joint piping. Terminal
point at HRSG edge. Condensate discharge in local condensate traps should be arranged by
Customer.
5.5 THERMAL INSULATION

To support superior performance, avoid spills, and protect operators from potential accidents, the
supply will include the realization of the thermal insulation. The insulation density and thickness, as
well as the outer surface coating, are to be defined according to the specific configuration of the plant
and to the type of circuit to be insulated. Insulation for the following components is included:
 thermal recovery circuits (hot water);

 the exhaust gas piping;
 the exhaust gas cleaning system;
 exhaust gas heat exchanger for steam production.
MEASURE TECHNOLOGIES
5.6 NATURAL GAS FLOW METER
This measurement system, installed on the natural gas supply system, features the following:
 a volumetric flow meter, complete with transmitter; and

 an electronic volume corrector, able to automatically correct the measured volume of gas to
the volume at given reference conditions (Sm3/h) by using measured values of pressure and
temperature acquired by the built-in sensors, complete with factory inspection certificate.
5.7 HOT WATER FLOW METER (HT CIRCUIT)

This measurement system, installed on the hot water circuit, features the following:
 a magnetic flow meter, complete with transmitter and LCD display;

 a pair of temperature sensors with respective thermowells; and
 a thermal energy calculator, with a display for visualization of energy consumption,
instantaneous measurements, and error messages.
5.8 HOT WATER FLOW METER (LT CIRCUIT)

This measurement system, installed on the hot water circuit, features the following:
 a magnetic flow meter, complete with transmitter and LCD display;

 a pair of temperature sensors with respective thermowells; and
 a thermal energy calculator, with a display for visualization of energy consumption,
instantaneous measurements, and error messages.
5.9 STEAM FLOW METER

This measurement system, installed on the steam circuit, features the following:
 a factory calibration certificate;

 a vortex precession flow meter, complete with transmitter and LCD display;
 a temperature sensor with respective thermowell;
 a pressure measurement device, complete with transmitter; and
 a thermal energy calculator, to calculate of the steam mass flow and the thermal power.
6 NOISE BARRIER
Supply and installation of noise barrier, composed of soundproofing metal galvanized and painted
panels, suitable to obtain the required noise levels.
The supporting metal framework will be made with HE steel profiles, sized according to the wind
forces required by current legislation and complete with base plate for fixing to the structure with
bolts. The structure is hot galvanized and polyester powder coated with oven polymerization.
The supporting metal framework is classified with CE marks as:
1. Execution class EXC2 according UNI EN 1090-1;

2. Welding performed by qualified welders according UNI EN 9606-1. Certified procedures of
welding according UNI EN 15614-1 based on WPS;
3. Weld examination according UNI EN 9712:2012, acceptability criteria Level C UNI EN ISO
5817 based on CnD procedure;
The noise-absorbing panels are classified as type TW 115AV10 and they are composed by of
different layers:
 External shell in galvanized steel and painted;

 Mineral wool layer 80 mm density 90 kg/mc;
 Internal layer performed on six different diameters (from 2.5 to 7 mm) in galvanized steel
and painted;
 The top of the panel is in propylene;
 The acoustic characteristics are DIalfa=20dB, DLr=28dB.
The design of the barrier is included as well as the phonometric survey at the end of the works.
7 SERVICES
7.1 ON SITE DELIVERY
As per the Supply Offer.
7.2 ON SITE UNLOADING

7.3 ON SITE ASSEMBLY

7.4 COMMISSIONING
The plant’s commissioning phase is a time of critical importance, in which ECOMAX®’s performance
is proved and the warranty period of the system is initiated. The system test is carried out as soon
as verification of all subcomponents is complete and connections of power and control systems are
energized. ECOMAX® commissioning is carried out in two stages:
 “cold tests” in order to test plant signals by simulating manual and automatic performance
of each device; and
 “hot tests,” during which electrical parallel operation, engine carburation, and thermal
exchanges with user are carried out.
After the completion of the tests, AB technicians perform final adjustments and train customer
personnel.
The first filling of the glycol solution (water + ethylene glycol) is included only for the ECOMAX®
closed circuits and the battery acid.
Only for the closed ECOMAX® cooling circuits are included the first filling of the glycol
mixture and the acid for the engine batteries.
7.5 ENGINEERING AND DOCUMENTATION

Engineering includes a project of study and development, as well as executive drawings according to
current legislation. At work completion, the following documentation will be issued:
 as-built layout (civil works, cable trail, and grounding system);

 as-built P&ID;
 technical documents for installed components;
 final technical reports;
 CE declaration of conformity; and
 area classification according EN 60079-10.
8 SUPPLY LIMITS
8.1 AB SUPPLY LIMITS
Feeding gas for ECOMAX®: At the inlet flange on the ECOMAX®;
emergency shutoff valve installed.
Dissipation circuits: All Included.
Hot water customer side: Flange on the ECOMAX®; customer side pump
not included.
Feeding water: Flange on the HRSG; feedwater pumps are
supplied loose.
Exhaust gas: All included, stack height as specified.
Steam customer side: Flange on the HRSG.
Compressed air: Not included.
Lube oil system: Inside tank included as described above; first

filling oil excluded.
Draining circuits: On the outside of the ECOMAX® package.
MV Power connections: Excluded. Limit at the generator plugs.
LV Ecomax® auxiliaries power supply: Excluded. Limit at the control panel plugs.
Grounding system: The system design for the foundation and

equipotential connections inside the ECOMAX®
unit is included; the supply and installation of
components (flexible wire rope, pegs, etc.) is
excluded and is the responsibility of the
building contractor.
NOTE
The information provided in this document reflects a standard Ecomax® system and is provided only
as an example. It is not definitive and is subject to change during the detailed design phase. The
inspiring philosophy, however, will not change. It remains focused on optimizing the manufacturing,
implementation, and operation of a superior system by implementing all measures and technical
decisions deemed to be the most suitable during the detailed design phase.
AB - SCOPE OF WORK
1 ECOMAX® CONFIGURATION
Code Description Included Not included
1.1 Noise insulated, weatherproof engine enclosure for √

outdoor installation. Sound pressure level as
indicated in the reference conditions (measured in
a free field environment without acoustic
reflection).
1.2 Internal and external protective coating on the √

ECOMAX®.
1.3 Doors fitted with handles, locks, and door stops. √
1.4 Forced draught ventilation system, complete with √

variable-frequency drive (VFD) regulation.
1.5 Motor operated air outlet louver dampers. √
1.6 Air intake filter. √
1.7 Insect screen on air intake and outlet system. √
1.8 Inlet air preheating system for a minimum ambient X

temperature of -20 °C.
1.9 Inlet air preheating system for a minimum ambient X

temperature of -25 °C.
Scope of work 1
1.10 ECOMAX® plant operation and maintenance √
manual.
1.11 ECOMAX® as-built documentation. √
2 GENSET AND MECHANICAL COMPONENTS, PRE-INSTALLED AT AB

FACILITIES
2.1 Spark-ignition gas engine. √
2.2 Three-phase generator. √
2.3 Engine control panel. √
2.4 Preassembled fuel gas train. √
2.5 Preassembled pre-chamber gas train. √
2.6 Gas pipework to the engine inside the ECOMAX® √

engine room.
2.8 Starting batteries and charging rectifier. √
2.9 Preassembled pipework on the high temperature √

(HT) engine cooling system inside the ECOMAX®.
2.10 Water circulation pump and three-way control √

valve mounted on the HT engine cooling system.
2.11 Expansion tank on the HT engine cooling system. √
2.12 Hot water flow meter (HT). √
2.13 Hot water flow meter (LT). √
2.14 Heat recovery system on the HT engine cooling √

system with a plate heat exchanger.
2.15 Preassembled pipework on the low temperature √

(LT) engine cooling system (2nd stage intercooler
circuit).
2 Scope of work
2.16 Water circulation pump and three-way control √
valve mounted on the LT engine cooling system
(2nd stage intercooler circuit).
2.17 Expansion tank on the LT engine cooling system. √
2.18 Automatic daily lube oil make-up system, installed √

inside the ECOMAX® engine room with a fresh oil
daily tank. Oil excluded.
2.19 Automatic lube oil filling system, installed inside the √

ECOMAX® (capacity 1.000 + 1.000 liters). Oil
excluded.
2.20 Heat recovery system on the LT engine cooling √

system with a plate heat exchanger.
3 ELECTRICAL AND CONTROL COMPONENTS, PRE-INSTALLED AT AB

FACILITIES
3.1 ECOMAX® plant control panel (for auxiliary √

systems).
3.2 Generator braker panel for coupling of the module X

to the grid.
3.3 Electrical preheating system. √
3.4 Parasitic load measurement system to measure √

tax-exempt electricity production.
3.5 Siemens PROFINET bus communication system. √
3.6 Equipment to automatically synchronize the √

module with the grid.
3.7 Siemens WinCC SCADA system to provide remote √

control of equipment.
Scope of work 3
3.8 Graphic display of operation data as a diagram for √
easy analysis and management of the ECOMAX®
plant.
3.9 A personal computer with monitor, keyboard, and √

mouse.
3.10 Single-phase UPS system that provides emergency √

power to the PC for process monitoring.
3.11 Firebox for ECOMAX® remote management (ADSL). √
3.12 Customer connection via an analogue modem. √
3.13 Alarm phone dialer. √
3.14 Profibus or Modbus connection. √
3.15 Electrical connections inside the ECOMAX®. √
3.16 Lighting system and emergency lighting system √

inside the ECOMAX®.
3.17 Smoke and gas detection system installed inside √

the ECOMAX®, complete with alarm unit.
3.18 Emergency stop buttons used to quickly stop the √

ECOMAX® plant.
3.19 System and devices for the management and √

control of the hot water EGHE.
3.22 Epoxy resin step-up transformer. X
3.23 Equipotential connections inside the ECOMAX®. √
3.25 QMTMR - MV panel with neutral ground resistor √

and measurement compartments.
3.26 GOP1 - MV panel with overvoltage protection. √
4 Scope of work
4 EQUIPMENT AND AUXILIARIES TO BE INSTALLED ON-SITE
4.1 Air conditioning unit for the ECOMAX® control √

room.
4.2 Galvanized safety fence on the ECOMAX® roof to √

protect all personnel who have access to it.
4.3 Galvanized ladders with safety cages for safe access √

to the ECOMAX® roof.
4.4 Shelter device above each door for protection √

against atmospheric agents.
4.5 Dry cooler with variable-frequency drive (VFD) √

regulation.
4.7 Heat recovery pipes in prefabricated spools with √

bolts and gaskets.
4.8 Insulation for water pipe spools. √
4.9 Automatic lube oil filling system, skid mounted and X

designed for outdoor installation (capacity 1.000 +
1.000 l). Oil excluded.
4.10 Fuel gas flow meter with spool. √
4.11 Gas servo valve for emergency shutoff. √
4.12 Steam boiler complete with exhaust gas piping and √

bypass.
4.13 Insulation for the steam boiler. √
4.14 Exhaust gas piping made of stainless steel, √

complete with supports, expansion joints, and
emission monitoring ports.
4.15 Insulation for the exhaust gas piping. √
4.16 Insulation for the exhaust gas silencers. √
Scope of work 5
4.17 Exhaust gas silencers (n° 3 silencers). √
4.18 Exhaust gas stack. √
4.19 Insulation for the exhaust stack. √
4.20 Condensate drainage system. Terminal point at the √

condensate drain on the ECOMAX® plant.
4.21 Oxidation catalyst. X
4.22 Selective catalytic reduction (SCR) exhaust gas √

treatment system, using urea.
4.23 Natural gas compressor. X
4.24 QMT12 - MV coupling panel. X
4.25 Gas pipe connection X
4.26 11 kV Circuit Breaker with surge arrester - supply √

loose (Max. 20 m far from to the alternator).
4.27 Noise barrier √
5 ON SITE WORKS.
5.1 Packaging for land transport. √
5.3 Assistance for on-site assembly. X
5.4 On-site assembly, to be performed by skilled AB √

technicians.
5.5 Commissioning. √
5.6 Contract crane and Offload and position of the X

container on concrete basement.
6 Scope of work
6 EQUIPMENT AND AUXILIARIES DELIVERED LOOSE FOR ON SITE
ASSEMBLY
6.1 Empty √
Scope of work 7
ANNEXE
ENGINE DATSHEET
10/2018
Technical Description
Genset
JGS 620 GS-N.L
dyn. GC Profile 1 (150ms/30%)
Electrical output 3352 kW el.
Emission values
NOx < 500 mg/Nm³ (5% O2) | < 190 mg/Nm³ (15% O2)
22.10.2018/DB (87CA) JGS 620 J11 70-95.docx Copyright ©(rg)

established by authorized sales provider from GE Jenbacher GmbH & Co OG 1/12
0.01 Technical Data (at genset) __________________________________________ 3
Main dimensions and weights (at genset) 4
Connections 4
Output / fuel consumption 4
0.02 Technical data of engine ___________________________________________ 5
Thermal energy balance 5
Exhaust gas data 5
Combustion air data 5
Sound pressure level 6
Sound power level 6
0.03 Technical data of generator _________________________________________ 7
Reactance and time constants (saturated) at rated output 7
connection variant 1K _________________________________________________ 8
0.05 Cooling water circuit ______________________________________________ 9
Oil - heat (Engine jacket water cooling circuit) 9
Engine jacket water - heat (Engine jacket water cooling circuit) 9
Mixture Intercooler (1st stage) (Engine jacket water cooling circuit) 9
Mixture Intercooler (2nd stage) (Low temperature circuit) 9
0.10 Technical parameters _____________________________________________ 10
0.20 Mode of Operation _______________________________________________ 11

0.01 Technical Data (at genset)
100% 75% 50%

Power input [2] kW 7.473 5.732 3.990
Gas volume *) Nm³/h 787 603 420
Mechanical output [1] kW 3.431 2.573 1.715
Electrical output [4] kW el. 3.352 2.510 1.660
Heat to be dissipated (calculated with Glykol 30%) [5]

~ Intercooler 1st stage (Engine jacket water cooling circuit) [9] kW 925
~ Intercooler 2nd stage (Low temperature circuit) kW 203
~ Lube oil (Engine jacket water cooling circuit) kW 347
~ Jacket water kW 547
~ Surface heat ca. [7] kW 234
Spec. fuel consumption of engine electric [2] kWh/kWel.h 2,23 2,28 2,40
Spec. fuel consumption of engine [2] kWh/kWh 2,18 2,23 2,33
Lube oil consumption ca. [3] kg/h 0,69 ~ ~
Electrical efficiency 44,9% 43,8% 41,6%
Fuel gas LHV kWh/Nm³ 9,5

*) approximate value for pipework dimensioning
[_] Explanations: see 0.10 - Technical parameters
All heat data is based on standard conditions according to attachment 0.10. Deviations from the standard conditions can result in
a change of values within the heat balance, and must be taken into consideration in the layout of the cooling circuit/equipment
(intercooler; emergency cooling; ...). In the specifications in addition to the general tolerance of ±8 % on the thermal output a
further reserve of +5 % is recommended for the dimensioning of the cooling requirements.

Main dimensions and weights (at genset)
Length mm ~ 8.900
Width mm ~ 2.200
Height mm ~ 2.800
Weight empty kg ~ 34.600
Weight filled kg ~ 35.700
Connections
Jacket water inlet and outlet DN/PN 100/10
Exhaust gas outlet [C] DN/PN 600/10
Fuel Gas (at genset) [D] DN/PN 100/10

Water drain ISO 228 G ½''
Condensate drain mm ~
Safety valve - jacket water ISO 228 [G] DN/PN 2x1½''/2,5
Lube oil replenishing (pipe) [I] mm 28
Lube oil drain (pipe) [J] mm 28
Jacket water - filling (flex pipe) [L] mm 13
Intercooler water-Inlet/Outlet 1st stage DN/PN 100/10
Intercooler water-Inlet/Outlet 2nd stage [M/N] DN/PN 65/10
Output / fuel consumption

ISO standard fuel stop power ICFN kW 3.431
Mean effe. press. at stand. power and nom. speed bar 22,00
Fuel gas type Natural gas
Based on methane number | Min. methane number MZ 70 | 70 d)
Compression ratio Epsilon 11,5
Min. fuel gas pressure for the pre chamber bar 4,13
Min./Max. fuel gas pressure at inlet to gas train bar 4 - 8 c)
Max. rate of gas pressure fluctuation mbar/sec 10
Maximum Intercooler 2nd stage inlet water temperature °C 44
Spec. fuel consumption of engine kWh/kWh 2,18
Specific lube oil consumption g/kWh 0,20
Max. Oil temperature °C 80
Jacket-water temperature max. °C 95
Filling capacity lube oil (refill) lit ~ 765
c) Lower gas pressures upon inquiry

d) based on methane number calculation software AVL 3.2 (calculated without N2 and CO2)

0.02 Technical data of engine
Manufacturer GE Jenbacher
Engine type J 620 GS-J11
Working principle 4-Stroke
Configuration V 60°
No. of cylinders 20
Bore mm 190
Stroke mm 220
Piston displacement lit 124,75
Nominal speed rpm 1.500
Mean piston speed m/s 11,00
Length mm 5.542
Width mm 1.900
Height mm 2.540
Weight dry kg 15.000
Weight filled kg 16.000
Moment of inertia kgm² 69,21
Direction of rotation (from flywheel view) left
Radio interference level to VDE 0875 N
Starter motor output kW 20
Starter motor voltage V 24
Thermal energy balance

Power input kW 7.473
Intercooler kW 1.128
Lube oil kW 347
Jacket water kW 547
Exhaust gas cooled to 180 °C kW 1.141
Exhaust gas cooled to 100 °C kW 1.571
Surface heat kW 135
Exhaust gas data

Exhaust gas temperature at full load [8] °C 386
Exhaust gas temperature at bmep= 16,5 [bar] °C ~ 432
Exhaust gas temperature at bmep= 11 [bar] °C ~ 490
Exhaust gas mass flow rate, wet kg/h 18.021
Exhaust gas mass flow rate, dry kg/h 16.904
Exhaust gas volume, wet Nm³/h 14.234
Exhaust gas volume, dry Nm³/h 12.844
Max.admissible exhaust back pressure after y-pipe mbar 50
Combustion air data

Combustion air mass flow rate kg/h 17.482
Combustion air volume Nm³/h 13.528
Max. admissible pressure drop at air-intake filter mbar 10

Sound pressure level
Aggregate a) dB(A) re 20µPa 101
31,5 Hz dB 88
63 Hz dB 95
125 Hz dB 101
250 Hz dB 99
500 Hz dB 94
1000 Hz dB 93
2000 Hz dB 92
4000 Hz dB 94
8000 Hz dB 95
Exhaust gas b) dB(A) re 20µPa 123
31,5 Hz dB 112
63 Hz dB 121
125 Hz dB 131
250 Hz dB 119
500 Hz dB 117
1000 Hz dB 118
2000 Hz dB 117
4000 Hz dB 112
8000 Hz dB 98
Sound power level

Aggregate dB(A) re 1pW 122
Measurement surface m² 125
Exhaust gas dB(A) re 1pW 131
Measurement surface m² 6,28
a) average sound pressure level on measurement surface in a distance of 1m (converted to free field) according to DIN 45635,
precision class 3.
b) average sound pressure level on measurement surface in a distance of 1m according to DIN 45635, precision class 2.
The spectra are valid for aggregates up to bmep=22 bar. (for higher bmep add safety margin of 1dB to all values per increase of 1
bar pressure).
Engine tolerance ± 3 dB

0.03 Technical data of generator
Manufacturer AVK e)
Type DIG 142 f/4 e)
Type rating kVA 4.800
Driving power kW 3.431
Ratings at p.f. = 1,0 kW 3.352
Ratings at p.f. = 0,8 kW 3.332
Rated output at p.f. = 0,8 kVA 4.165
Rated reactive power at p.f. = 0,8 kVar 2.499
Rated current at p.f. = 0,8 A 219
Frequency Hz 50
Voltage kV 11
Speed rpm 1.500
Permissible overspeed rpm 1.800
Power factor (lagging - leading) 0,8 - 0,95
Efficiency at p.f. = 1,0 97,7%
Efficiency at p.f. = 0,8 97,1%
Moment of inertia kgm² 192,00
Mass kg 11.300
Radio interference level to EN 55011 Class A (EN 61000-6-4) N
Cable outlet left
Ik'' Initial symmetrical short-circuit current kA 1,54
Is Peak current kA 3,93
Insulation class F
Temperature (rise at driving power) F
Maximum ambient temperature °C 40
Reactance and time constants (saturated) at rated output

xd direct axis synchronous reactance p.u. 2,06
xd' direct axis transient reactance p.u. 0,20
xd'' direct axis sub transient reactance p.u. 0,14
x2 negative sequence reactance p.u. 0,15
Td'' sub transient reactance time constant ms 20
Ta Time constant direct-current ms 120
Tdo' open circuit field time constant s 3,85
e) GE Jenbacher reserves the right to change the generator supplier and the generator type. The contractual data of the
generator may thereby change slightly. The contractual produced electrical power will not change.

connection variant 1K
established by authorized sales provider from GE Jenbacher GmbH & Co OG

0.05 Cooling water circuit
Oil - heat (Engine jacket water cooling circuit)

Nominal output kW 347
Max. Oil temperature °C 80
Loss of nominal pressure of engine jacket water bar 0,40
Safety valve - max press. set point bar 3,50
Engine jacket water - heat (Engine jacket water cooling circuit)

Max. engine jacket water temperature (outlet engine) °C 95
Engine jacket water flow rate m³/h 68,5
Mixture Intercooler (1st stage) (Engine jacket water cooling circuit)

Max. inlet cooling water temp. (intercooler) °C 74,8
Nominal pressure of cooling water / (max. operating pressure) PN 10
Loss of nominal pressure of engine jacket water bar 0,50
Mixture Intercooler (2nd stage) (Low temperature circuit)

Max. inlet cooling water temp. (intercooler) °C 44
Aftercooler water flow rate m³/h 45,0
Nominal pressure of cooling water / (max. operating pressure) PN 10
Intercooler water pressure drop bar 0,60
The final pressure drop will be given after final order clarification and must be taken from the P&ID order documentation.

0.10 Technical parameters
All data in the technical specification are based on engine full load (unless stated otherwise) at specified
temperatures and the methane number and subject to technical development and modifications.
All pressure indications are to be measured and read with pressure gauges (psi.g.).
(1) At nominal speed and standard reference conditions ICFN according to DIN-ISO 3046 and DIN 6271,
respectively
(2) According to DIN-ISO 3046 and DIN 6271, respectively, with a tolerance of +5 %.
Efficiency performance is based on a new unit (immediately upon commissioning).Effects of
degradation during normal operation can be mitigated through regular service and maintenance work.
(3) Average value between oil change intervals according to maintenance schedule, without oil change
amount
(4) At p. f. = 1.0 according to VDE 0530 REM / IEC 34.1 with relative tolerances, all direct driven pumps
are included
(5) Total output with a tolerance of ±8 %
(6) According to above parameters (1) through (5)
(7) Only valid for engine and generator; module and peripheral equipment not considered (at p. f. = 0,8),
(guiding value)
(8) Exhaust temperature with a tolerance of ±8 %
(9) Intercooler heat on:
* standard conditions - If the turbocharger design is done for air intake temperature > 30°C w/o de-
rating, the intercooler heat of the 1st stage need to be increased by 2%/°C starting from 25°C.
Deviations between 25 – 30°C will be covered with the standard tolerance.
* Hot Country application (V1xx) - If the turbocharger design is done for air intake temperature >
40°C w/o de-rating, the intercooler heat of the 1st stage need to be increased by 2%/°C starting from
35°C. Deviations between 35 – 40°C will be covered with the standard tolerance.
Radio interference level

The ignition system of the gas engines complies the radio interference levels of CISPR 12 and EN 55011
class B, (30-75 MHz, 75-400 MHz, 400-1000 MHz) and (30-230 MHz, 230-1000 MHz), respectively.
Definition of output
• ISO-ICFN continuous rated power:
Net break power that the engine manufacturer declares an engine is capable of delivering continuously,
at stated speed, between the normal maintenance intervals and overhauls as required by the
manufacturer. Power determined under the operating conditions of the manufacturer’s test bench and
adjusted to the standard reference conditions.
• Standard reference conditions:
Barometric pressure: 1000 mbar (14.5 psi) or 100 m (328 ft) above sea level
Air temperature: 25°C (77°F) or 298 K
Relative humidity: 30 %

• Volume values at standard conditions (fuel gas, combustion air, exhaust gas)
Pressure: 1013 mbar (14.7 psi)
Temperature: 0°C (32°F) or 273 K
Output adjustment for turbo charged engines

Standard rating of the engines is for an installation at an altitude ≤ 500 m and combustion air
temperature ≤ 30 °C (T1)
Engine room outlet temperature: 50°C (T2) -> engine stop
If the actual methane number is lower than the specified, the knock control responds. First the ignition
timing is changed at full rated power. Secondly the rated power is reduced. These functions are carried
out by the engine management system.
Exceedance of the voltage and frequency limits for generators according to IEC 60034-1 Zone A will lead
to a derate in output.
Parameters for the operation of GE Jenbacher gas engines

The genset fulfils the limits for mechanical vibrations according to ISO 8528-9.
The following "Technical Instruction of GE JENBACHER" forms an integral part of a contract and must be
strictly observed: TA 1000-0004, TA 1100 0110, TA 1100-0111, and TA 1100-0112.
Transport by rail should be avoided. See TA 1000-0046 for further details
Failure to adhere to the requirements of the above-mentioned TA documents can lead to engine damage
and may result in loss of warranty coverage.
Parameters for the operation of control unit and the electrical equipment
Relative humidity 50% by maximum temperature of 40°C.
Altitude up to 2000m above the sea level.
0.20 Mode of Operation

Grid Parallel Mode
The genset is running in parallel to the utility. The unit load can be adjusted via its power control set point
or designated option.
Procedure in the event of mains failure:
When the mains monitor relay (protective relay ANSI No. 27, 59, 81, 78- provided either by GE or the
customer) is activated due to a mains failure, the engine is isolated from the mains by opening the
generator breaker. The module is shut down without any cool-down run.

Island operation is not available in this case!
The module can be restarted following the restoration of mains power after a 5-minute mains stabilization
period.

ANNEXE
LAYOUT
ANNEXE
FUNCTIONAL DIAGRAM
SUPPLY OFFER
Esteemed:
GA PET FOOD PARTNERS

Plocks Farm,
Liverpool Road, Bretherton,
Leyland UK
Offer: QUO-04365-J5W3V4-REV.5
Orzinuovi, 23/10/2018
COMMERCIAL PROPOSAL FOR CHP PLANT: ECOMAX® 33 NGS – outdoor solution
We hereby submit our offer for the design, construction, commissioning and testing of no. 01 CHP
system for outdoor installation as described in the attached Technical Specification 17-05-2018 REV.5.
The proposed system is designed to produce both electrical power and thermal power recovered as
hot water and steam.
The unit is set-up with no. 01 generating set, series GE Jenbacher J 620 GS-J12 type, electrical output
3.352 kW (gross rating at a power factor = 1).
CHP emissions concentration will comply with the following requirements:
NOx 5% O2 < 75 mg/Nm³
CO 5% O2 < 100 mg/Nm3
NH3 5% O2 < 5 mg/Nm3
The scope of works includes:
• No. 01 Module ECOMAX® 33 NGS;

• Exhaust gas recovery system for steam production;
• Hot water flow meter (HT/LT circuit), steam flow meter, natural gas flow meter;
• SCR system;
• Noise barrier;
• Lube oil system 1000+1000 l;
• Thermal insulation;
• Transport;
• On-site assembly and insulation;
• Commissioning;
Price of the AB Impianti’s scope of supply proposed for the project is (VAT excluded):
Euro 2,192,000.00
COMMERCIAL CONDITIONS:
Offer validity 60 days.
VAT: To be added if applicable.
Delivery: DAP, Incoterms 2010. The Equipment will be delivered at the

Customer’s site and will be ready for the start-up within 10
months from the receipt by AB of the payment of the down-
payment.
Warranty: 12 months from the Plant start-up, but not later than 18 months
after the shipment of the main component of the Plant from our
factory, whichever expires first.
The warranty will be valid only if the Plant will operate in
accordance with the correct functioning procedures, as indicated
by the user instruction and maintenance manuals provided upon
delivery.
Payment terms - 30 % At the signature of the Supply Offer.

- 40 % At the issue of the Notice of Goods Ready to Ship and in
any case before the shipment.
- 20 % Upon the completion of the installation of the Equipment
at site.
- 10 % At the Final Test of the Equipment.
Exclusions and supply limits:

See attached technical specification:
- Technical Specification 17-05-2018 REV.5;

Technical Description of ECOMAX 33 Natural Gas CHP

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TECHNICAL DESCRIPTION OF

ECOMAX® 33 NATURAL GAS

ECOMAX® 33 NATURAL GAS

Ecomax® 33 - Electrical output (at generator terminals) 3.352 kW

Total thermal output as saturated steam at 10 barg (184,1 °C) 1.133 kW

Steam flow 1.814 kg/h

Total thermal output as hot water at 90 °C 1.996 kW

Island mode operation Not included

Black start capability Not included

NOx (reported at 5% O2) 450 mg/Nm³

Atmospheric emissions of co-generator, with SCR, are:

NOx (reported at 5% O2) 75 mg/Nm³

4.1 CARBON STEEL CASING

4.2 NOISE INSULATION

4.3 VENTILATION SYSTEM

4.3.1 Inlet air system, equipped with:

4.3.2 Outlet air systems, equipped with:

 surface preparation and washing;

4.5 MAIN THERMAL CIRUITS

 connecting piping on jacket water circuit up to the plate heat exchanger;

4.6 PLATE HEAT EXCHANGER ON HT RECOVERY CIRCUIT

4.7 PLATE HEAT EXCHANGER ON LT RECOVERY CIRCUIT

4.8 LUBE OIL SYSTEM

4.10 EXHAUST GAS PIPING

4.11 EXHAUST GAS SILENCERS

4.12 MODULE-INTEGRATED SAFETY

4.13 SMOKE AND GAS DETECTION SYSTEM

4.14 EMERGENCY DRY COOLER

4.15 ANTI-EXPLOSION SERVO ACTUATED VALVE

4.16 UNIT CONTROL PANEL

 generator circuit breaker status;

A G59 grid protection relay will be provided.

 easy control and adjustment operations;

 local and remote command management;

 display of plant performance;

4.17.2 Graphics Pages

4.17.3 PROFINET/Profibus network

 the proper application of standards, and

5.1 EXHAUST GAS CLEANING SYSTEM (SCR).

 annealed tubesheets, submitted to normalisation heat treatment;

5.3 EXHAUST GAS CIRCUIT WITH BY-PASS

5.4 CONDENSARET DRAINAGE.

5.5 THERMAL INSULATION

 thermal recovery circuits (hot water);

 a volumetric flow meter, complete with transmitter; and

5.7 HOT WATER FLOW METER (HT CIRCUIT)

 a magnetic flow meter, complete with transmitter and LCD display;

5.8 HOT WATER FLOW METER (LT CIRCUIT)

 a magnetic flow meter, complete with transmitter and LCD display;

5.9 STEAM FLOW METER

 a factory calibration certificate;

The supporting metal framework is classified with CE marks as:

1. Execution class EXC2 according UNI EN 1090-1;

 External shell in galvanized steel and painted;

7.2 ON SITE UNLOADING

7.3 ON SITE ASSEMBLY

7.5 ENGINEERING AND DOCUMENTATION

 as-built layout (civil works, cable trail, and grounding system);

Steam customer side: Flange on the HRSG.

Compressed air: Not included.