Heavy-Duty Continuous Operating Natural Gas Generator

Property Specification

Type: Heavy-Duty Continuous Operating Natural Gas Generator Package

Features: This power generation plant features integrated low-temperature and high-temperature (LT & HT) fluid circulation pumps driven directly by the prime mover, ensuring optimal thermal management under ISO 3046/1 testing standards. The unit achieves electrical conversion efficiencies reaching up to 44.2% at full output rating, while thermal energy performance scales up to 54.4% during partial load conditions. Energy consumption ranges from 2,453 kW (8.4 MMBTU/hr) at 50% load up to 4,525 kW (15.4 MMBTU/hr) at maximum 100% continuous demand. Temperature management relies on thermostatically controlled inlet and outlet fluid regulation, fully calibrated for pipeline natural gas at a lower heating value (LHV) of $33.44\text{ MJ/Nm}^3$ (905 BTU/ft³). The overall system meets major international manufacturing and operational benchmarks, including ISO 8528, ISO 3046, AS 2789, DIN 6271, and BS 5514.

Applications: Engineered for continuous base-load installations, this system delivers steady electrical energy for constant facility loads operating with unrestricted annual run hours. It is well-suited for combined heat and power (CHP) installations, district heating networks, and heavy industrial thermal processes that require both electrical yield and usable heat recovery. Additionally, it provides reliable primary power for off-grid operations, data centers, manufacturing plants, and utility microgrids demanding uninterrupted output without capacity restrictions.

Description

Technical Parameters

Parameter / Specification Standard Value / Details Load-Dependent Performance (100% / 90% / 75% / 50%)
Engine Brand & Model
Cummins HSK78G (12 Cylinders, V-Type)
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Fuel Type & Requirements
Pipeline Natural Gas / Min. Methane Index: 40
MN Requirement: 70 / 60 / 50 / 45
Engine Displacement
78 L (4,778 cu. in.)
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Aspiration & Configuration
Turbocharged and Charge Air Cooled
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Cylinder Bore x Stroke
190 mm x 230 mm (7.48 in x 9.06 in)
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Operating Speed
1,500 RPM
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Engine Lubrication Capacity
617 L (163 gal)
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Full Load Lube Oil Consumption
0.2 g/kWe-h (0.15 g/hp-h)
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Electrical System Voltage
24 VDC Starter
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Inlet Fuel Supply Pressure
0.3 bar (0.15–0.45 bar) / (2.17–6.53 psi)
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Fuel Consumption (ISO 3046/1)
Lower Heating Value (LHV)
4,525 kW (15.4 MMBtu/h) / 4,122 kW (14.1 MMBtu/h) / 3,476 kW (11.9 MMBtu/h) / 2,453 kW (8.4 MMBtu/h)
Electrical Efficiency (ISO 3046/1)
Percentage (%)
44.2% / 43.7% / 43.2% / 40.8%
Thermal Efficiency (ISO 3046/1)
Percentage (%)
49.1% / 49.3% / 50.6% / 54.4%
Electrical Power Output
Continuous Rating
2,000 kWe / 1,800 kWe / 1,500 kWe / 1,000 kWe
Heat Dissipation – Low Temp (LT)
Circuit Rejection kW (Btu/min)
127 kW (7,222 Btu/min) / 119 kW (6,767 Btu/min) / 111 kW (6,312 Btu/min) / 94 kW (5,346 Btu/min)
Heat Dissipation – High Temp (HT)
Circuit Rejection kW (Btu/min)
1,200 kW (68,243 Btu/min) / 1,062 kW (60,395 Btu/min) / 884 kW (50,272 Btu/min) / 642 kW (36,510 Btu/min)
Radiated Heat Loss
Ambient Radiation kW (Btu/min)
214 kW (12,170 Btu/min) / 193 kW (10,975 Btu/min) / 163 kW (9,269 Btu/min) / 113 kW (6,426 Btu/min)
Exhaust Heat Recovery
Available Thermal Energy to 105°C
897 kW (50,965 Btu/min) / 853 kW (48,509 Btu/min) / 763 kW (43,391 Btu/min) / 599 kW (34,064 Btu/min)
Combustion Air Intake Flow
Volumetric Airflow
5,380 ft³/min (2,539 l/s) / 4,820 ft³/min (2,275 l/s) / 4,070 ft³/min (1,921 l/s) / 2,770 ft³/min (1,307 l/s)
Exhaust Gas Volumetric Flow
Flow Rate
12,810 ft³/min (6,046 l/s) / 11,750 ft³/min (5,545 l/s) / 10,180 ft³/min (4,804 l/s) / 7,430 ft³/min (3,507 l/s)
Exhaust Gas Mass Flow
Flow Rate
3.22 kg/s (25,556 lb/h) / 2.89 kg/s (22,937 lb/h) / 2.43 kg/s (19,286 lb/h) / 1.66 kg/s (13,177 lb/h)
Exhaust Gas Temperature
Turbine Outlet Temperature
390°C (734°F) / 405°C (761°F) / 426°C (799°F) / 474°C (885°F)
Exhaust System Backpressure
Max Permissible
1.45 in-Hg (4.9 kPa) across all load levels
HT Circuit Coolant Volume
Fluid Capacity
284 L (75 gal)
HT Coolant Circulation Rate
Flow @ Max Restriction
99 m³/h (438 gal/min)
HT Coolant Operating Temperatures
Max Inlet / Outlet Temp
Inlet: 78°C (172°F) / Outlet: 90°C (194°F)
HT Circuit Max Pressure Drop
External Restriction Limits
Max Drop: 130 kPa (18.9 psi) / Max Static Head: 18.3 m (60 ft)
LT Circuit Coolant Volume
Fluid Capacity
49 L (13 gal)
LT Coolant Circulation Rate
Flow @ Max Restriction
42 m³/h (187 gal/min)
LT Coolant Operating Temperatures
Max Inlet / Nominal Outlet
Inlet: 50°C (122°F) / Outlet: 53°C (128°F)
LT Circuit Max Pressure Drop
External Restriction Limits
Max Drop: 130 kPa (18.9 psi) / Max Static Head: 18.3 m (60 ft)
Nitrogen Oxides (NOx)
Exhaust Emission Rate @ 5% O₂
493 mg/Nm³ (0.94 g/hp-h) / 489 mg/Nm³ (0.94 g/hp-h) / 494 mg/Nm³ (0.97 g/hp-h) / 490 mg/Nm³ (1.01 g/hp-h)
Carbon Monoxide (CO)
Exhaust Emission Rate @ 5% O₂
980 mg/Nm³ (1.65 g/hp-h) / 992 mg/Nm³ (1.68 g/hp-h) / 1,008 mg/Nm³ (1.73 g/hp-h) / 1,014 mg/Nm³ (1.83 g/hp-h)
Total Hydrocarbons (THC)
Exhaust Emission Rate @ 5% O₂
1,500 mg/Nm³ (2.87 g/hp-h) / 1,549 mg/Nm³ (2.98 g/hp-h) / 1,646 mg/Nm³ (3.22 g/hp-h) / 1,817 mg/Nm³ (3.76 g/hp-h)
Alternator Make & Model
Mecc Alte ECO 46 VL/4 A
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AC Output Configuration
400V, 3-Phase, 50 Hz
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Apparent Power Rating
2,500 kVA
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Voltage Regulation & AVR
Automatic Voltage Regulator DER1 (±0.5%)
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Insulation & Thermal Limits
Class H Insulation / Class F Temperature Rise
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Enclosure Protection & Airflow
IP23 Ingress Protection / Cooling Air: 135 m³/min
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Alternator Dry Weight
5,114 kg
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Open Frame Overall Dimensions
6,950 mm L x 2,288 mm W x 2,895 mm H (21.5 ft x 7.5 ft x 9.5 ft)
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Overall Open Set Dry Weight
60,000 kg
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