CHP (VA Dallas Case Study)

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CHP (VA Dallas Case Study)
Technologies 1
Dallas VA Medical Center
A CHP Case Study
Design Build Delivery of a Combined Heat and
Power (CHP) Project for a Federal Client
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Agenda
1. Introductions
2. Project Overview
3. Vision
4. Construction Activities
5. Challenges/Lessons Learned
6. Q&A
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Introductions
Mike McLaughlin, PE
Vice President of Engineering
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Jeff Gunlicks
Project Manager
Project Overview
Dallas VA Medical Center
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The referral center for VA North Texas Health Care System
A major teaching and medical research center.
An 84 acre campus less than 10 miles south of Dallas
Providing a wide range of medical specialties
Includes 544 beds and over 1 million sf of healthcare space
Project Overview
Existing Central
Utility Plant
Electrical Support
Building
Turbine Yard
Project Scope
• Add a 4.6 MW natural gas fired turbine to an existing
central energy plant.
• Replace an existing steam boiler with a dual fuel fired Heat
Recovery Steam Generator (HRSG) to replace an existing
steam boiler.
• Integrate electricity into the existing 11MW usage.
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Project Vision
What were the project goals?
• Reducing operating costs and saving energy
• Leveraging renewable energy and improve “Green” footprint
• Energy Security
Why was CHP chosen?
• Consistent demand for power and heat.
• Integrated well with existing infrastructure
• Improved energy independence
Where did the owner start?
• Feasibility study that assessed the economical, technical and
funding options.
• Investigation included Biodiesel, Landfill Gas and Biomass and
conventional (natural gas)
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Traditional System
Heat
Power
45%
Efficient
Power Plant
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Boiler Plant
Combined System
Heat
Power
80%
Efficient
Generator
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Heat Recovery
Combined Heat & Power
Power
Gas fired engines
½ – 2.5 MW
Heat
Heating Water
180F-220F
Micro Turbines
½ - 1 MW
Dallas VA
Gas Turbines
5 – 50 MW
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Steam
25,000lbs/hr
400,000 lbs/hr
Combined Heat & Power
Heat
Power
Generator
Air Inlet
Filter
Bypass Duct
Gas
Turbine
Diverter
Valve
Turbine
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Heat
Recovery
Steam
Generator
Supplementary
Burner
Heat Recovery
Combined Heat & Power
Heat Recovery Steam Generator
Heat
A custom piece of equipment design and
fabricated to meet the project requirements
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Essentially a large water tube boiler using
turbine exhaust heat as heat source
Heat
Recovery
Steam
Generator
Supplementary
Burner
Actual Dallas VAMC HRSG during hydrostatic
pressure test
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Heat Recovery
Project Schedule
DESIGN
CONSTRUCTION
MAR
APR
MAY
DRAWINGS COMPLETE
DRAWINGS ISSUED FOR
CONSTRCTUION
CONSTTRUCTION STARTS
Aug 2011: Proposal Submitted
JUN
JUL
AUG
SEP
OCT
NOV
DEC
JAN
FEB
MAR
Dec 2013: NG Pipeline Complete
Dec 2013: Target Turnover
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APR
CONSTRUCTION COMPLETE
FEB
2013
TUBRINE DELIVERED
JAN
PURHCASE HRSG
CONTRACT SIGNED
DEC
2012
PURCHASE TURBINE
2011
CHP Construction
Equipment Delivery & Rigging:
Considerations:
• Access to site
• Space for cranes to set up
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Turbine
CHP Construction
Equipment Delivery & Rigging:
Considerations:
• Access to site
• Space for cranes to set up
• Size of doors in facility
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HRSG
CHP Construction
Equipment Delivery & Rigging:
Considerations:
• Access to site
• Space for cranes to set up
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NG Compressor
CHP Construction
Site Construction:
Considerations:
• Accessibility
• Noise & Emissions
• Proximity to Utilities
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CHP Construction
Site Construction:
Turbine exhaust
Inlet Air Chilling Coils
Generator and Turbine
(Inside Enclosure)
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CHP Construction
Site Construction:
Main Stack
Economizer
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Steam Connection Water Tube Boiler
Fuel Train
Exhaust
from Turbine
Duct Burner
CHP Construction
Natural Gas Supply:
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Availability of Natural Gas will dictate
size/cost of the Natural Gas
Compressor.
Turbine required 230 psig natural
gas.
Existing gas supply was 20 psig which
would have required a 300 HP
compressor.
Government opted to contract for a
dedicated 100-180 psig natural gas
line which dropped NG Compressor
to 100 HP saving significant energy
Start up currently waiting on
completion of NG line.
CHP Construction
Other Considerations:
1.
Construction in an operating Central Energy Plant
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2.
Shut-downs/high risk operations: Hot tap, Electrical tie-ins
Working closely with the end-user throughout the duration of
the project facilitated:
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Deliver the owner products that meet
their needs
(example: sight glass change out).
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Facility operators become familiar with
equipment, and manufacturers
representatives.
RFI’s answered quickly with design-build
delivery and access to end user.
Extensive training at facility turnover for
the operators.
CHP Construction
Other Considerations:
3.
Manufacturers Representatives are vital to the effort
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4.
Planning for Long Lead Items
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5.
Production of Shop Drawing
Payment Schedule and Financing
Allow for innovation and design flexibility (design-build):
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Coordination is critical
Expertise is invaluable
Alternative Solutions within the contractual requirements
Improved performance with cost savings
Summary
Benefits:
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Improved energy efficiency
Energy Independence
Opportunities to leverage renewable energy sources
Environmental Stewardship
Options:
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Available for systems from ½ MW to 50+ MW
Heat is available as heating hot water or steam
Systems can utilize packaged or custom equipment
Unique Considerations:
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Design to best match your application
Construction offers different challenges that traditional construction.
Financing and Utility Rebates are commonly available.
Select qualified partners to and contract delivery methods
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Questions
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