Co Generation Plant at McMaster University Implementation and Lessons Learned

Transcription

1 Canadian Assciatin f University Business Officers (CAUBO) Cnference Presentatin June, 2017 C Generatin Plant at McMaster University Implementatin and Lessns Learned Dr. Mhamed Attalla, P.Eng., FCSCE Assistant Vice President & Chief Facilities Officer

2 Agenda 1. McMaster University - Overview 2. McMaster University - Energy Prfile 3. C Gen at McMaster Assessment 4. Prject Implementatin and Schedule 5. Lessns Learned 6. Phts

3 The Campaign fr McMaster University The Campaign fr McMaster University McMaster University Overview McMaster University is a public research university that is lcated in Hamiltn, Ontari and was funded in 1887 Over 30,000 undergraduate students Over 4,000 graduate students Apprximately 7,500 emplyees (staff & faculty) Cmprised f 59 buildings within the main campus with a ttal building flr area f mre than 500,000 square meters.

4 The Campaign fr McMaster University The Campaign fr McMaster University McMaster Energy Ecnmic Prfile Electricity is the mst expensive cmmdity n campus. Energy and water cnsumptin n campus is driven by the intensive research activities, campus ppulatin, facilities utilizatin and weather. Energy rates ($/kwhr, $/m3 f gas) are driven by the prvincial market and is based n energy demand and gvernment adjustments. With the increase in energy cnsumptin and electricity rates, higher energy csts are frecasted fr the University. 18% Energy Cst Breakdwn by Cmmdity ( ) 11% Electricity Csts Natural Gas Csts Water Csts 71%

5 The Campaign fr McMaster University The Campaign fr McMaster University McMaster Energy Csts 2002 t 2016 $12,000,000 $10,000,000 $8,000,000 University Energy Csts $10,052,352 $9,408,478 $6,000,000 $4,000,000 $2,000,000 $5,163,329 $4,010,391 $3,922,955 $2,327,837 $0 Electricity Csts Natural Gas Csts

6 McMaster Energy Cnsumptin Campus Electricity Cnsumptin ( ) Campus Natural Gas Cnsumptin ( ) Electricity kwh (Millins) , , ,720 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, Annaul Electricity Cnsumptin per student (kwh/student/year) Natural Gas - m3 (Millins) Annual natural gas cnsumptin per student (m3/student/year) Net Electricity Cnsumptin Electricity Cnsumptin / Student / Year Net Natural Gas Cnsumptin Natural Gas Cnsumptin / Student / Year

7 McMaster Energy Intensity Trends Electricity Intensity / year / m2 Gas Intensity / year / m2 Electricity Intensity (kwh/m2-year) Gas Intensity (m3/m2-year)

8 McMaster Energy Cnsumptin Frecast Electricity Kwh (Millins) Campus Grid Electricity Cnsumptin Trend / Frecast ( ) Natural Gas - m3 (Millins) Natural Gas Cnsumptin Trend / Frecast ( ) Net Electricity Cnsumptin kwhr's Net Natural Gas Cnsumptin m3 Electricity rates are expected t increase n average annually by % in the perid (2013 Ontari Lng Term Energy Plan). Assciatin f Majr Pwer Cnsumers expect an annual rate increase f 4 6 %. Lng-term frecasts indicate lw natural gas rates due t the discvery f additinal reserves f shale natural gas within eastern Nrth America Increasing electricity rates represent an increase f apprximately $ $1M / year.

9 McMaster Energy Prfile Energy Trends : Net Cnsumptin Cnsumptin/student/year Cnsumptin/m 2 /year Electricity 79,400,000 kwh 81,900,000 kwh 4,500 kwh/student/yr 2,700 kwh/student/yr 238 kwh/m2/yr 180 kwh/m2/yr Gas 11,500,000 m 3 10,700,000 m m3/student/yr m3/student/yr 34 m3/m2/yr 24 m3/m2/yr Cmpared t an NRCAN Survey, McMaster University gas and electricity intensity is belw prvincial average and marginally abve the Canadian average.

10 Assessment f Cgeneratin / Trigeneratin Systems In 2013, McMaster University cmpleted a Financial Feasibility and Assessment f Implementing a BEHIND THE METER Cgeneratin / Trigeneratin System Reprt; Identify IESO Prgrams t encurage industrial, cmmercial and institutinal custmers t implement electricity efficiency initiatives that require capital expenditures Electricity, steam and chilled water culd be prduced much mre efficiently and cst effectively if a Trigeneratin system were t be implemented McMaster s heat t pwer rati, based n average seasnal lads (kw), is within the range f 0.6 : 1 2 : 1 which is suitable fr a natural gas turbine generatr as it is mre efficient at prducing steam. An internal cmbustin engine wuld be better suited fr a ht water distributin system. Recmmendatin; natural gas turbine cupled with a heat recvery steam generatr (HRSG), a natural gas fired duct burner, and an absrptin chiller, which culd prvide; Baselad pwer requirements ( MW) t reduce cnsumptin frm the IESO grid Generate steam frm waste heat fr space heating and dmestic water requirements Reduce electrical cnsumptin via absrptin technlgy t augment the chilled water capacity during the cling seasn

11 Assessment f Cgeneratin / Trigeneratin Systems In 2014, McMaster cmpleted a Detailed Engineering Study f Cgeneratin, recmmending; A Trigeneratin system: 5.7 MW natural gas fired turbine (des nt perate with fuel il) HRSG with a nminal steam utput f 29,000 lbs/hr unfired cnditin Duct Burner supplementing steam generatin t 119,000 lbs/hr fully fired Absrptin chiller 1000 tns f cling utilizing 18,000 lbs/hr steam A 2500 tn centrifugal chiller t replace an inefficient 5000 tn centrifugal chiller A dedicated cmpressr t supply natural gas t the turbine. Electrical lad represents apprximately 5% f the pwer generated by the Turbine The utilizatin f the E T Clarke Plant t huse the new equipment Brwnfield Prject Remval f tw ut f service bilers t prvide space fr the turbine & HRSG Remval f 5000 tn chiller t prvide space fr the new centrifugal and absrptin chillers Use f existing biler #4 breeching / chimney stack fr exhaust gases frm turbine Asbests Abatement requirements Remval f ut f service incineratr t prvide space fr the natural gas cmpressr equipment Replacement f electrical switchgear within E T Clarke

12 Financial Feasibility fr a Cgeneratin / Trigeneratin System Simple Payback N Incentives 10 years Prject Estimate $22,000,000 Annual Electricity Savings $4,800,000 Additinal Fuel Csts $2,200,000 Additinal O&M $500,000 Simple Payback Incentives & Deferred Maintenance 4.5 years Prject Estimate $22,000,000 Incentive - IESO Industrial Acceleratr Prgram $7,600,000 (5 installment payments) Incentive Unin Gas $40,000 Annual Electricity Savings $4,800,000 Additinal Fuel Csts $2,200,000 Additinal O&M $500,000 Savings Deferred Maintenance $6,000,000 (replacement f biler #4 current pririty, biler #4 draft fan, replacement f chiller #5) Anticipated Electricity Savings 47,000 MWh / year

13 McMaster University - Prfile McMaster Trigeneratin System Chiller Cnfiguratin; N. G. Cmpressr Equipment Chiller # tns Chiller # tns Chiller # tns Chiller # tns New Absrptin Chiller 1000 tns New Centrifugal Chiller 2500 tns Ttal Capacity = 14,500 tns Peak chilled water lad = 8,200 tns B5 B4 HRSG Steam Generatin Cnfiguratin; B3 HRSG / Duct Burner 116,000 lbs/hr Back-up & Supplemental B3 100,000 lbs/hr B5 200,000 lbs/hr B4 160,000 lbs/hr (breeching dampered with turbine) Peak steam lad 116,000 lbs/hr Minimal summer steam lad 10,000 lbs/hr C5 C1 C2 C3 N. G. Turbine 2500 tn Centrifugal 1000 tn Absrptin

14 Trigeneratin System Schematic Ecnmiser 115 kv 13.8 kv

15 Planning Prject Schedule TASK START FINISH Initial Assessment Reprt Dec March 2013 Initial Capacity Screening (ICS) Applicatin & Transmissin Cnnected Custmers Small Embedded Generatr Assessment August 2015 Detailed Engineering Study July 2014 December 2014 Verificatin f N. G. Fuel Supply - Unin Gas July 2014 Cnnectin Impact Assessment (CIA) Sept IESO Measurement & Verificatin Plan (CLEAResult) May 2015 Octber IESO Prject Incentive Agreement Octber 2015 Amendment t the Envirnmental Cmpliance Apprval (ECA) February 2017 Engineering Design Prime Cnsultant February 2015 Octber 2017 Turbine Specificatin / Tender / Award February 2016 July 2016 HRSG Specificatin / Tender / Award March 2016 July 2016 Chillers Specificatin / Tender / Award August 2016 December 2016 Natural Gas Cmpressr Specificatin / Tender / Award August 2016 January 2017 Demlitin / Abatement - Phase 1 May 2016 January 2017 Electrical Switchgear Phase 2 March 2016 January 2017 Prime Cntractr Phase 3 January 2017 Octber 2017

16 Lessns Learned Envirnmental Cmpliance Apprval (ECA) Air and Nise. A campus wide assessment is t be cmpleted as ppsed t a building specific apprach. Nise mitigatin is required frm all surces t ensure cmpliance at the nearest receptr. Silencers required fr surces f nise, i.e. intake & exhaust lcatins. New envirnmental regulatins under the recently annunced Ontari Cap and Trade prgram may affect verall prject csts. Ptential charge f $10 / metric tn f CO2 prduced. Authrity Having Jurisdictin TSSA, ESA, City f Hamiltn Building Department permit & apprvals. Practive apprach f infrmatin exchange and submittals. Electrical intercnnectin required acceptance by Hydr One Netwrks. System requires t perate in parallel with Hydr One, shrt circuit capacity study was required. Mnitring and cntrl requirements by Hydr One that ensures that n electricity is back fed t the IESO grid. Unique Agreement between McMaster and HHS (Bay Area Health Trust manages the C Gen system at the Hspital) that required review, discussin, negtiatin, fr the supply f electricity & steam. Prject financial risk related t the US $ - Canadian $ currency exchange as majr equipment was t be surced frm the US.

17 Lessns Learned Cnt d Prequalificatin f the cnsultants, cntractrs, and certain suppliers. Prcurement f lng lead time equipment required a.s.a.p. Wrked with cntracts, legal with Suppliers t establish and negtiate Supply Agreements, that were eventually handed ver t the Prime Cntractr. Fast tracking f prject was necessary t meet with the expectatins f the IESO incentive cntract scheduling requirements. Installatin f revenue grade meters are required fr the generatr utput and fr the n. g. cmpressr pwer lad (parasitic lad) that will verify the verall system perfrmance t IESO. Brwn Field Prject - Cnstructin activities within an peratinal plant. Ntificatins, interruptins, evacuatins fr crane lifts, relcatin f services, prvisins f a laydwn area, traffic cntrl, Health & Safety always paramunt. A separate natural gas statin was required t be installed fr the turbine. An easement was required t be established fr the gas main ruted t E T Clarke supplying the turbine. Lng Term Maintenance f system is critical t meet efficiency requirements and system life cycle expectatins. 4 year service agreement established fr turbine system maintenance.

18 Prject Implementatin Equipment within the E T Clarke Plant

19 Prject Implementatin Rf Wrks

20 Prject Implementatin Wrks and Preparatin within the E T Clarke Plant

21 Prject Implementatin Crane Lift f HRSG