LoadTracker CHP Installation, Commissioning and Maintenance

CHP Installation

Where plant room space for CHP installation is restricted, SAV Systems offer additional flexibility by using cabin-type enclosures. Additional combined heat and power capacity can thus be added without having to extend plant rooms. CHP installation enclosures are designed to a robust specification, with steel floor, ventilation louvres, multiple access doors and pre-wired circuits. Prefabrication is made at works, with transportation to site for final lowering into position. External surfaces can be supplied painted to match clients’ preferred colour scheme. The combined heat and power equipment can then be rapidly introduced, ready for connection to site services.

CHP Commissioning

Site requirements for CHP unit commissioning can vary significantly, and SAV maintain a flexible stance.

Pre-commissioning visits are instrumental in removing the causes for potential interruptions following CHP installation. Complete commissioning of Combined Heat and Power Units can be undertaken at sites anywhere in the UK and ROI. Where heat pumps are part of a CHP Energy Centre, commissioning of such units is undertaken at the same time.

Standard commissioning for each CHP installation project is rigorous and multi-disciplinary. Allowance is made for personnel induction and CHP training at site before commencement of the work. Besides checking that the CHP installation conforms to the project schematics and that all connections are secure, commissioning includes the following:

  • Priming of all hydraulic circuits and first start-up of all equipment
  • Optimisation of gas/air mix using flue gas analysis
  • Verification that fume extraction is safe.

Arrangements can be made by SAV Systems for attendance at site to supplement combined heat and power commissioning activities; for instance, where client requirements call for system-wide testing of the LTHW pipe work or the BMS. Contractors sometimes ask for demonstration visits as part of the process of equipment handover to the site operator following CHP installation.

Mains Monitoring Relays (G59/2)

To comply with Engineering Recommendation G59/2 (2010) regulations relating to embedded generating plant, every LoadTracker Combined Heat and Power control panel comes with a Mains Monitoring Relay.

Fundamentally, this is for the protection of the electricity grid. Each District Network Operator (DNO) needs to verify that supplies feeding in are within tolerance on variables such as voltage, frequency and phase shift. The Mains Monitoring Relay is the protective interface for these variables, designed to trip the associated CHP in the event of divergence beyond acceptable limits.

SAV Systems can help with the procurement, completion and submission of the appropriate DNO application forms, to ensure compliance by the combined heat and power Energy Centre with section G59/2. It is important to note that failure to lodge this document with the relevant DNO in sufficient time would lead to permission for electricity generation by the CHP being denied. SAV recognise this as a potential source of frustration in CHP installation projects and are resourced up for pre-emptive action.

CHP Systems Troubleshooting

Post-commissioning experience is often a direct reflection of the care taken during the design stage. An important objective for combined heat and power projects is to ensure smooth, uninterrupted operation and secure the maximum running time for the CHP unit. SAV Systems extend whatever assistance is necessary to the preparation of plant room schematics and layouts, and are happy to become involved at the early stages of design. Issues which receive close attention include the matching of CHP output to site load patterns. Where appropriate, recommendations about pipe work connections local to the combined heat and power unit can be given with a view to reducing system return temperatures. This greatly increases the effectiveness of thermal storage capacity and lengthens CHP running periods.

Interruptions to CHP service are usually the result of increasing return temperatures with resultant overheating of the engine. Wherever repeated unwanted stoppages occur, SAV are prepared to become involved in the diagnosis and solution of the underlying cause. Having invested in a LoadTracker CHP Energy Centre, the last thing an owner wants (never mind SAV) is to have the combined heat and power unit remain out of service!

Additional capacity for CHP Systems

Where projects are planned to be developed in stages, SAV can arrange to install Combined Heat and Power capacity sequentially. CHP connections to the main pipe work can be sized to accommodate additional power units according to project schedule, thus reducing future disturbance to a minimum. By matching the output potential of installed capacity with stepped project demand, the LoadTracker CHP Energy Centre should always have sufficient load to work at full capacity.

LoadTracker CHP Maintenance

SAV Systems provide a generous warranty of 24 months with every LoadTracker CHP Unit. Servicing is recommended at intervals of 8,000 operating hours (for the XRGi 15G), or 6,000 hours (for the XRGi 20G), or 2 years from previous service if sooner. LoadTracker combined heat and power control panels transmit operating data via modem, enabling diagnostics at a distance. Further details are given on the LoadTracker CHP Maintenance Contract, available on request.

For further information about these, or any other aspects of CHP servicing, feel free to contact us:

by phone: 01483 771910

by e-mail: info@sav-systems.com