Combined Run Gasifier and CHP Engine
Commissioning test
1. Pre- start safety review meetings
The Aston team has undertaken a full review of the measures in place to prepare the Gasifier and
CHP Engine for the commissioning test. A Risk Assessment and a Safe Operating Procedure have
been prepared and circulated among all the relevant people.
A number of safety review meetings have taken place involving the EBRI team, Graham Faulks
(Deputy Director of Estates), David White (Fire Safety Officer) and Gez Cooney (EAS Technical
Manager).
The EBRI staff involved in the test is:
Muhammad Saghir, Plan Manager
Clara Serrano, Senior Engineer
Jim Scott, Research Fellow
Dan Wright, Research Fellow
Thiruvilan Arakkonam, Plant Engineer
Wehrle Werk will be running the gasifier:
Christian Eder
Christoph Kornmayer
Andreas Niglas
A number of engineers have been hired for this commissioning test:
Control engineer for the gasifier: Mr Hilmes
Control engineer for the engine: Dennis Eichenauer
Control engineer for the load matching system: Chris Marklew, from Marklew.Net
Engine specialists: Phil Starr and Dan Best (GMI Power) and Paul Johns (CRA Europe)
Project manager: Jeremy Mayes from Otto Simon Ltd.
Mechanical engineer: Michel Wray from Otto Simon Ltd.
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2. Preparation week
The gasifier package will be preparing during the week of the 01.09.2015, ready for the test
campaign in the week of the 07.09.2015. This is a phase of inspection and checking and some
cold commission the gasifier has not run for some time so all components to be checked.
1. List of the equipment to be checked:
1.1. Function test of each cycle with all relevant components (syngas, cooling water, cold
water, thermal oil, compressed air, nitrogen, flare) including:
-
Positions of hand valves, check the whole compressed air, nitrogen system, cooling water
system, cold water system, thermal oil system, syngas system, natural gas system.
Function test of the overpressure release syphon with air
Function test of all pumps.
Function test of level measurements
Function test of the limit and flow switches
Function of the pressure measurements
Calibration of the gas analyzer
Cleaning and test of the centrifuge
1.2. Filling in the new scrubbing oil with conditioning of demulsifier
2. Completion of the new pipework installation:
-
Installation of the isolation valve to the CHP
Installation of the gas flow meter to the CHP
Pressure test of the pipework
Cold commissioning of the equipment
Testing of the wiring installation
3. Cold gasifier test
At the end of the week a test run will be undertaken in cold mode without wood pellets of the
complete plant.
4. Engine test
The CHP Engine also needs to be checked and a further test will be run to ensure it is fully
operational and ready to receive syngas. The LMS control system functionality to be verified.
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3. Test campaign. Execution week
Monday: 7/09/2015
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Cold commissioning of the new equipment.
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Programming works: Mr. Hilmes and Chris Marklew.
Tuesday: 8/09/2015
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Gasifier heating up to 900°C, electrical heating and then combustion
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Programming works: Mr. Hilmes and Chris Marklew.
Wednesday 09/09/2015
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Reheating the gasifier up to 900°C and shift to gasification at about 09:00 am.
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Gasifier-engine test run. Start and stop tests to control the safety features, regulating
the gasifier near to the CHP maximum demand of syngas.
-
Gasifier back to combustion mode and shut down overnight.
-
Further programming with minor modifications can be carried out in parallel
o
M. Hilmes is leaving the site in the afternoon.
o
Dennis Eichenauer will be on site Wednesday and Thursday.
Thursday 10/09/2015
-
Reheating the gasifier up to 900°C and shift to gasification at about 09:00 am.
-
Gasifier-engine test run. Start and stop tests to control the safety features, regulating
the gasifier near to the CHP maximum demand of syngas.
-
Gasifier back to combustion mode (burning out char in the bed material) and shut down.
-
Further programming with minor modifications can be carried out in parallel
o
Dennis Eichenauer will be on site.
Friday 11/09/2015
-
Clean up the plant. Wehrle will be leaving the site at about 10:00 am.
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Combined Run Gasifier and CHP Engine
Monday
Tuesday
Wednesday
Thursday
Friday
Gasification plant
Contractors
Mr Hilmes
Mr Hilmes
Mr Hilmes (half-day)
EBRI and
Muhammad Saghir
6:00am – 2:00pm
6:00am – 2:00pm
6:00am – 2:00pm
Muhammad Saghir
Wehrle staff
Thiruvilan Arakkonam
Christoph Kornmayer
C. Kornmayer
Christian Eder
T. Arakkonam
Thiruvilan Arakkonam
Clara Serrano
Thiru Arakkonam
1:00pm – 9:00pm
1:00pm – 9:00pm
1:00pm – 9:00pm
Christian Eder
Christian Eder
C. Kornmayer
Clara Serrano
Thiru Arakkonam
Clara Serrano
(Tuesday to
Thursday,
2 shifts)
Christian Eder
Christoph Kornmayer
Andreas Niglas
(Wehrle until 10:00
am)
Engine and Load Matching System
Contractors
Varlowe
Paul Johns
Dennis Eichenauer
Dennis Eichenauer
Chris Marklew
Chris Marklew
Chris Marklew
Chris Marklew
EBRI staff
Jim Scott and Dan Wright
Plant Manager
Muhammad Saghir (plant inductions and First Aider)
Deputy Plant Manager
Clara Serrano (internal coordinator and Fire warden)
Coordination
Jeremy Mayes (Project Manager) and Michael Wray (Mechanical Engineer), from Otto Simon Ltd.
Security
Ext. 4803 and Channel 2 in radios
Combined Run Gasifier and CHP Engine
Results
CHP Thermal output, kW
600
500
400
300
200
100
0
Combined Run Gasifier and CHP Engine
Power to the Load bank, kW
350
300
250
200
150
100
50
0