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TECHNOLOGY DESCRIPTION Large- and medium-scale gas-fired turbines have been used to generate electricity since the 1950s. Technical and manufacturing developments during the last decade have enabled the introduction of microturbines with generation capacities ranging from 30 to 200 kW. The IR PowerWorks System is one of the first cogeneration installations that integrates microturbine technology with a heat recovery system. The following description of the IR PowerWorks System was provided by the vendor and does not represent verified information. Electric power is generated with an integrated Ingersoll-Rand microturbine with a nominal power output of 70 kW (59 °F, sea level). The system incorporates a gas generator compressor, recuperator, combustor, power turbine, and electric generator. Air enters the unit and is compressed to about 35 psig in the gas generator compressor and then heated to around 1,000 °F in the recuperator. A screw compressor type fuel booster is used to compress the natural gas fuel, the compressed air is mixed with the fuel, and this compressed fuel/air mixture is burned in the combustor under constant pressure conditions. The resulting hot gas is allowed to expand through the power turbine section to perform work, rotating the turbine blades to turn a generator that produces electricity. The rotating components are of a two-shaft design with the power turbine connected to a gearbox and supported by oil lubricated bearings. The generator is cooled by air flow into the gas turbine. The exhaust gas exits the turbine and enters the recuperator, which captures some of the thermal energy and uses it to pre-heat the air entering the combustor, improving the efficiency of the system. The exhaust gas then exits the recuperator through a muffler and into the integrated IR heat recovery unit. The integral heat recovery system consists of a fin-and-tube heat exchanger, which circulates a mixture of approximately 16 percent propylene glycol (PG) in water through the heat exchanger at approximately 20 gallons per minute (gpm). The heating loop is driven by an internal circulation pump and no additional pumping is required. The thermal control system is programmable for individual site requirements. Minimum settings may vary, but the maximum fluid temperature entering the PowerWorks may never exceed 200 °F. The IR PowerWorks system includes an induction generator that produces high-frequency alternating current (AC) at 480 volts. The unit supplies an electrical frequency of 60 hertz (Hz) and is supplied with a control system which allows for automatic and unattended operation. An active filter in the turbine is reported by the turbine manufacturer to provide clean power, free of spikes and unwanted harmonics. The power unit operates at 44,000 revolutions per minute (rpm), and the generator operates at 3,260 rpm regardless of load. VERIFICATION DESCRIPTION Verification of the IR PowerWorks was conducted at the Crouse Community Center in Morrisville, New York. The facility is a 60,000-square foot skilled nursing facility providing care for approximately 120 residents. The IR PowerWorks system was installed to provide electricity to the facility and to provide heat for domestic hot water (DHW) and space heating. During normal occupancy and facility operations, electrical demand exceeds the IR PowerWorks generating capacity, and additional power is purchased from the grid. On rare occasions, when facility electrical demand is below 70 kW (demand can drop as low as 50 kW in some instances), the excess power is exported to the grid. In the event of a power grid failure, the system is designed to automatically shut down to isolate system from grid faults. When grid power is restored, the IR PowerWorks system can be restarted manually. S-2 SRI/USEPA-VS-GHG-VR-21 April 2003PDF Image | THE ENVIRONMENTAL TECHNOLOGY VERIFICATION PROGRAM
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