1. business and industrial
2. energy
3. electricity

Ohio Energy
Workshop Q
Case Study: Combined Heat &
Power (CHP) Installation Using
Microturbine Technology …
Potential for Industry to Generate
Electricity & the Economics
Tuesday, February 18, 2014
3:15 p.m. to 4:30 p.m.
Biographical Information
Tom Fitzpatrick, PE, Power Department Manager
SSOE Group, 1001 Madison Ave. Toledo, Ohio 43604
Phone: 567.218.2328
Fax: 419.255.6101
[email protected]
Tom has over 30 years of experience in the power industry and serves as SSOE’s
Power Department Manager. In this role he is responsible for the management of
various utility related projects for industrial, municipal, and institutional facilities. Tom
has been involved in various power plant and Combined Heat and Power (CHP)
projects. Most recently, he completed Boiler MACT studies for three confidential clients
as well as a CHP study for a University.
Tom received his Bachelor of Science in Environmental Engineering from Syracuse
University. In addition, he also holds a Master of Science in Mechanical Engineering
from Princeton University and a Masters of Business Administration in Finance from the
University of Toledo. Recently, Tom co-authored an article titled “What Now –
Complying with Major- and Area-Source Boiler Rules” in HPAC Engineering Magazine.
He is a registered Professional Engineer (PE) in seven states and a Certified Energy
Auditor (CEA) and works in SSOE’s Toledo, Ohio office.
Case Study: Combined Heat &
Power (CHP) Installation Using
Microturbine Technology
18th Annual Ohio Energy Management Conference
February 18, 2014
Tom Fitzpatrick, PE
Department Manager – Power Group
Agenda
• SSOE overview
• CHP project overview
• Installation and equipment overview
• Design and permitting
• Installation
• Commissioning
• Lessons learned
SSOE Group
Full-service, global EPCM firm
Founded in 1948
Privately-owned
ISO 9001:2008 certified
1,100+ associates
Core competency: project
management and project
delivery systems
• Leaders in Virtual Design
& Construction (VDC)
•
•
•
•
•
•
Our Mission
Company Mission
• We make our clients successful by delivering the
highest value engineering, architectural, and project
delivery services
Company Vision
• Be the company of choice by clients and employees
• Build a sustainable, global, project delivery
organization
• Provide career growth and wealth creation
opportunities for our employees
• Be a role model for support of environmental
sustainability
Value Promise
SSOE returned
of our fee in project savings to clients in 2013.
SSOE Office Locations – U.S.
Quality
• ISO 9001: 2008 certified
• Only one non-conformance finding in 15 years
• Annual third party surveillance audits at randomly
selected locations
• In-house Lean Six Sigma program – 3 Black Belts on
staff, supported by team of 11 Green Belts
• Goal of 5% efficiency improvements year over year
$1.5 million
2013 savings from Lean Six Sigma
Case Study: CHP Installation
Veterans Administration (VA) Hospital in Ann Arbor, MI
Installation of 1,000kW Microturbine CHP system to provide
electricity and steam to central utility plant
Case Study: CHP Installation
VA Hospital Complex – Energy Center
Case Study: CHP Installation
VA Hospital Complex – Energy Center
• DTE Energy – Electric and Natural Gas provider
• Four Cleaver Brooks Package Boilers 3@ 700 HP
1@ 500 HP – Generate 68 PSIG Saturated Steam
• Two 40 kV Circuits feed two 10 MVA transformers
• Chillers – Three 800 ton centrifugal units
• Natural Gas – 12” 100 psig line at street – 4” 5
psig line to Energy Center
Case Study: CHP Installation
VA Hospital Complex – Energy Use
• Average annual energy consumption
•
24,320 MWH Electric
•
130,000 MMBTU Natural Gas
• Typical loads
•
Electric: 2,500 kW baseload and 4,700 kW summer peak
•
Steam: 8,000 pph baseload and 30,000 pph winter peak
• Average annual utility costs
•
$2.4 Million ~$0.098 per KWH average
•
$0.52 Million ~$4 per MMBTU
Request for Proposals

800 KW min. cogeneration unit

Natural gas shall be the primary fuel.

The ability to use No. 2 fuel oil is
desired but not required.

Emissions of Nitrogen Oxides (NOx)
shall not exceed 0.4 lbs/MWH.

Require no lubricating oils or coolants.

The type of electrical generation
technology is to be determined by
the bidder.

There is a preference to use waste
heat to preheat combustion air;
however, the ultimate choice of
waste heat technology is to be
determined by the bidder.

Produce power at 277/480 60 Hertz
(Hz).

Sound levels, no more than 65 dba @
10 ft.

All material and equipment used in
this project shall be standard
components, regularly manufactured
and available and not custom-built
especially for this project unless
approved by the VA-COTR.

Only domestic construction material
shall be used in performing this
project.
Project Summary
• CHP System integrated into existing central utility
plant steam and electrical system
• 1,000 kW Natural Gas microturbine with heat
recovery steam generator
• Using existing pad originally designed for another
package boiler
• Extend 5 psig natural gas line
• Tie into existing Energy Center Bus 2, 3200A, 480 volt
Design
• Design-Build project
• DeMaria Building Company (DBC) and SSOE Group
– Full mechanical and electrical integration
• Original feasibility study called for separate facility
for CHP unit located behind parking garage
– Ultimately integrated into existing energy center
– Tie into feedwater, water treatment, and blowdown systems
Permitting
• Air Permit only environmental permit to procure
• In addition to Energy Center the VA complex has
seven (7) diesel fired generators and one ethylene
oxide sterilizers
• VA Facility is a minor source of air pollutants
• Potential To Emit for 1,000 KW Unit
– NOx 1.8 TPY, CO 4.8 TPY, CO2 5,500 TPY
• Minor Source Permit To Install Required
– No Dispersion Modeling
– No Public Comment Period
– No CEMS Required
Equipment
• 1,000 kW Capstone natural gas microturbine
– (5) 200 kW units
– 1.375 MMBTU/hr. exhaust energy per module
• Cain Heat Recovery Steam Generator (HRSG)
– 2,300 Lbs. Steam/hr.
• One Boiler Feed Pump
• 2,000A, 480 Volt Breaker
• Metering with visible disconnect
• SEL relays
Capstone Turbine - Five 200kW Modules
Characteristic
Performance
Output
200kW net
Total System
Efficiency
70%
Fuel Flow
2,280,000 BTU/hr − HHV Steady State
Exhaust
Temperature
535°F (280°C)
Total Exhaust
Energy
1,350,000 BTU/hr
Emissions
NOx (<9 ppm) @ 15% O2
Noise Level
65 dBa at 10 meters
Voltage
480 VAC 3 phase, 4-wire wye. 60 Hz
SA Voltage
150−480 VAC, 50−60 Hz
Weight
2270kg (5,000 lbs). 7000 lbs for SA
Size
98”h x 67”w x 144”d
Cooling Potential
60 tons
Capstone Turbine – Package Assembly
200kW modules
combined in 40’ long
ISO container
package
C600
C800
C1000
Capstone Turbine – Microturbine Core
• Air bearings
– No oil or grease
• Air cooled
– No anti-freeze or liquids
• Variable speed
– Up to 98,000 rpm
Capstone Turbine – Power Electronics
• Inverter Based
– UL1741
Capstone Turbine
Inverter based vs. traditional generators
• Power electronics based 60Hz sine wave production with near
unity power factor.
– Combustion equipment can rotate at any frequency
– “Smart” inverters can generate Kvar’s as needed
• Lead/Lag and be programmed to support local grid conditions
• UL1741 inverter certification includes IEEE1547 compliance.
– Same as a Solar Array inverter
– Utilities may still want additional relaying external to the
inverter(s)
Capstone Turbine - Installed
Heat Recovery Steam Generator
• 68 psi VA System
– Up to 150psi
available
• 2,300 pph max
output from 1,000
KW system
HRSG
Installation
• Tie ins for gas, steam, blowdown, feedwater
• Platform Built over turbines for HRSG
• Full exhaust ductwork bypass of HRSG
• Use ambient air for combustion and cooling
• Electrical design
– Arc flash study
– Relay coordination study
– Short circuit analysis
• 40 month project schedule
– October 2011 notice to proceed
– January 2014 start-up
Installation – HRSG Platform
Installation – Gas and Electric
Stack – Match Existing
Expected Performance
Gross Generation - KW
Net Generation - KW
Unit Cost of Electricity - $/KWH
Savings in Electricty Cost - $/Hr
Flue Gas Temperature Entering HRSG - F
Flue Gas Temperature Leaving HRSG - F
Steam Flow - Lbs/Hr
Net Generation - BTU/Hr
Net Steam Produced - BTU/Hr
Total Useable Electricity and Heat - BTU/Hr
Heat Rate - BTU (HHV)/Gross KWH
Fuel Input - BTU/Hr
Overall Efficiency
Reduction in package Boiler Gas Use - BTUs/Hr
Net Increase in Natural Gas Use - BTUs/Hr
Cost of Natural Gas - $/MMBTU
Increase in Natural Gas Cost - $/HR
Net Savings in Power and Natural Gas Cost - $/HR
Potential Annual Power and Natural Gas Savings
300
273
$0.0980
$26.73
525
380
640
930,937
644,698
1,575,635
11,400
3,420,000
46.1%
786,217
2,633,783
$4.00
$10.54
$16.20
$141,873
1,000
938
$0.0980
$91.90
525
380
2,120
3,200,582
2,135,563
5,336,145
11,400
11,400,000
46.8%
2,604,345
8,795,655
$4.00
$35.18
$56.72
$496,850
Project Challenges
Electrical Interconnection
• Significant delays due to electrical utility
interconnection process.
• Start process early and plan plenty of schedule lag.
• Interconnection requirements may add non-trivial
unexpected costs.
Thank You!
Tom Fitzpatrick, PE
Department Manager, Power
SSOE Group
567.218.2328
[email protected]