For the ownersof alocal authority-owned anaerobic digestion (AD)plant, removingthe responsibility fortheir CHP enginesfrom a singleservice provider and handing itto twosmaller, expert companies–including gas engine upgradingspecialist Gen-C–has delivered big rewards. Not only have theirCHP maintenance costsbeen slashed but theirtwo MWM engines arenowmore reliable, easier to start and simpler to maintain, resulting in significantly increased uptime.Flexible supportPreviously, it was common for AD plantowners to tie themselves into lengthy CHP service contracts with a single, large provider to safeguardtheperformance and longevity of their engine. But following reports of disjointed communication, lengthy waits for engine restarts and expensive additional call-out charges, increasing numbers of plant operators are now turning to smaller, specialist firms to delivera more flexible and cost-effective solution.This has certainly proved the case for the operators of an AD plant situated on a local authority recycling parkin Bedfordshire.The 600kW facility converts over 30,000 tonnes of kerbside-collected food waste each year into renewable energyandemploys two MWM V12 CHP (combined heat and power) engines. When theplant owner’srelationship with their long-term engine service provider broke down, they were keen to find an alternative option that would offer local taxpayersbetter value for money. While the day-to-day CHP managementwas set to be managed by a third-party company that already handled the recycling park’s steam turbines, additional support fromreliable partnerswas also required forthe engines’ servicing and spares.“Wehad previously supplied the ownerswith high-quality CHP spareparts andhavea strong reputationwithin the waste and AD industryfor engine upgrading solutions,so when they approached us with this latest request, we were keen to help,”says Gen-C’sJames Thompson. “Having also developed a strong working relationshipwith servicing experts GenV, I knewthat we could once againwork together to deliver an expert, bespoke, value-for-money solution forthe waste recycling plant’sownersto ensure the continued reliable and efficient running of their CHPs.”Unlocking the keyto success
PRESS RELEASESpecialistCHP firms deliver big results forlocal authority AD planthttp://www.gen-c.co.ukPage 2of 3First on the agenda wasgainingaccess to the CHP control panels, which had been locked by theprevious service provider to prevent the owners from accessing them. Withoutdirectaccess,effective engine management would be impossible; anytime theCHPsstalled or shut down (for example,due to a change in biogas composition or bad weather), the operators would be unable to restart them and would incur significant and costly engine downtime while they waited for an engineer to arrive. Gen-C offereda unique solution –the supply and installation ofbrand-new, open-access Motortech control panels, fitted with the latest intelligent ComAp technology. This would give full control to the plant managers themselves, rather than a third-party service provider, and significantly increase engine uptime. Remote controlOpen-accesscontrol panels are the key to enablingoperators to leave a restrictive service contract. They allow CHP owners to dial in remotely at any time and from anywhere to manage their engines’ performance directly. Throughout the Covid-19 pandemic, this facility has proved especially popular with Gen-C’s customers, as it requires fewer personnel to be on site. The control panels also feature IGS-LOG softwareas standard. This monitoring technology enables managers to understand what constitutes normal operation for their engines and spot any downward trends or anomalies before they affect their smooth operation. In addition, the software issues an alert if a fault occurs and allows the operators to diagnose and rectify it themselves, and even remotely restart the engines; significantly reducing downtime. Satisfied with this solution, the plant ownerstook the decision to give both of the waste recovery park’sCHPengines a complete overhaul to kickstart their performance. The first CHP was out of action for just seven days, during which time it underwent a full E60 service by GenV and was fitted with an upgraded open-access control panel by Gen-C. Gen-C also installed a series of new and improved Motortech parts specific for biogas enginesto improve performance further, including a VariFuel gas mixer, an MIC4 ignition controller and a DetCon 20 detonation control system. The overhaul of the second engine was completed a month later, also taking just one week. The power of threeThe success of the collaboration between the twospecialist firms is already paying dividends. “Not only do the engines now start first time, every time, they also run much more smoothly,”explains James Thompson. “Should a simple issue cause either of the engines to temporarily shut down, the operators can now restart it themselves within seconds instead of waitingfor a service provider to respond. And if the cause is something more serious, they can assess it emotely and either fix it themselves or call us to have it up and running within hours, not days. This has resulted in increased engine uptime and better, more reliableperformance. And as theplant ownersare no longer tied into an expensive monthly service contract, their bills are significantly lower, too.Working in partnership alongside other specialist firms is something we’re used to doing and, as in this case, it can really pay off.”For more information on the Motortech open-access CHP control panel, contact info@gen-c.co.uk
