A recent engine and control panel upgrade by CHP support specialist Gen-C at Avocet Renewables’ 500kW biogas plant at Coston Hall Farm in Norfolk has delivered a 20% increase in power generation and enables 24/7 remote monitoring and management of the system.

This post contains sponsored content produced in partnership with Gen-C.

Avocet Renewables’ anaerobic digestion (AD) plant at Coston Hall Farm, Barnham Broom near Norwich uses agricultural inputs such as energy crops to generate biomethane and electricity, which is exported to the grid, as well as heat, which is used locally on the farm to dry crops. The 500kW V12 MAN E3262 engine was installed in 2017 to provide heat and generate electricity. Following a technical issue, Peterborough-based GenV Ltd were called in to maintain and support the engine. However, issues including a locked control panel limited GenV’s ability to optimise the CHP performance, so they turned to support partners Gen-C for assistance.

Limited by outdated controls

“The control system was old and because it was tied to the original supplier, we didn’t have access to change key aspects of the engine’s operation and couldn’t get to anything remotely,” explains Warren Vessey, Managing Director at GenV. “After 18 months of struggling with failing engine performance, we undertook a full R3 service and agreed with the customer to implement a number of upgrades, including a new open access control system, with the help of our long-term partner, Gen-C.”

In addition to replacing and upgrading the control panel, Gen-C from Yorkshire was also commissioned to upgrade the engine, restoring lost power and improving reliability.

“The engine was underperforming – only producing around 400kW – stuttering and vibrating badly, causing the customer to lose significant revenue,” said James Thompson, Managing Director of Gen-C. “The engine also had a mix of equipment from different brands, which we see quite often – the ignition controller, actuator, fuel mixer, pick-ups etc. were from different manufacturers, which impacted performance.”

Streamlining CHP operations

James continues: “To improve the overall performance, we have upgraded key components such as the mixer and throttle speed control. And because everything we install comes from one manufacturer (leading German brand Motortech), the customer now has one point of contact for all service and spares – as we are the sole Motortech agent for the UK. At the same time, we have removed the old controllers and display in the control panel and installed a new touchscreen with our controllers and expansion boards.

“The new open-access control system means that the AD operator, GenV and all of us can access the system remotely and make immediate changes if necessary, minimising downtime. The system also features smart diagnostics, with alerts based on user-defined parameters, and is backed by our 12 months of free remote technical support.”

Benefits of Remote Access

The most immediate benefit Avocet Renewables has enjoyed following the engine upgrade is that their CHP is now running at full capacity, resulting in a 20% increase in output. With new components designed to last for at least the next ten years, the engine also runs more smoothly, which will improve reliability, reduce downtime and reduce maintenance requirements.

“The open protocol on the new control panel gives us full access to the engine via remote monitoring. This means I can see everything that is happening and assist the Coston Hall Farm site at any time, wherever I am, making it much more efficient and user friendly,” emphasises Warren Vessey.

“Another great benefit for the customer is that they now have complete flexibility and choice over who handles their maintenance contract. It’s an industry-known system with readily available parts and support, so anyone can have access to it. It’s easy to use and any adjustments or modifications can be made from anywhere, which really helps to reduce downtime.”

The upgrade was only completed in mid-June, but Mark Gill, Plant Manager at Coston Hall Farm, is already positive: “The system is working well and is a lot faster than the old control panel. It is also much easier to operate and, most importantly, our CHP is running at full capacity again.”