UW Madison September 13, Wisconsin Public Utility Institute Gas: What s in the Pipeline?

Transcription

1 Wisconsin Public Utility Institute Gas: What s in the Pipeline? Making the Switch to Gas: Utility Infrastructure Needs and a Case Study of a Coal to Gas Plant Conversion Jeff Pollei, UW Madison Agenda Campus Overview and Utility Summary Evolution of Heating Plants CSHP Plant History CSHP Legal History Plant Dispatching Infrastructure Requirements 1

2 University of Wisconsin Overview Founded in Schools/Colleges Enrollment of 42,099 >18,500 Employees and Faculty 20.6 Million GSF on 935 Acre Main Campus (>27.0 Million Total) Campus Overview (Before March 2012) West Campus Cogeneration Facility (WCCF) 400,000 PPH Steam 20,000 Tons Chilled Water (Electric) 100 MW Combustion T/G (Nat. Gas) 68 MW Extraction/Condensing T/G Walnut Street Heating Plant (WSHP) 600,000 PPH Steam (Nat. Gas) 11,000 Tons Chilled Water (Electric) 9,000 Tons Chilled Water (Steam) Charter Street Heating Plant (CSHP) 500,000 PPH Steam (Coal) 300,000 PPH Steam (Nat. Gas) 26,000 Tons Chilled Water (Steam) 9.7 MW Back Pressure T/G Infrastructure Requirements 2

3 Campus Overview Campus Overview (January 2015) West Campus Cogeneration Facility (WCCF) 400,000 PPH Steam 30,000 Tons Chilled Water (Electric) 100 MW Combustion T/G (Nat. Gas) 68 MW Extraction/Condensing T/G Walnut Street Heating Plant (WSHP) 600,000 PPH Steam (Nat. Gas) 11,000 Tons Chilled Water (Electric) 9,000 Tons Chilled Water (Steam) Charter Street Heating Plant (CSHP) 900,000 PPH Steam (Nat. Gas New) 300,000 PPH Steam (Nat. Gas Existing) 26,000 Tons Chilled Water (Steam) 9.7 MW Back Pressure T/G Infrastructure Requirements 3

4 Campus Utility Summary Steam Summary 2,100,000 PPH Total (2014) 1,800,000 PPH Firm 1,316,000 PPH Peak Chilled Water Summary 76,000 Tons Total (2015) 67,500 Tons Firm 64,000+ Tons Peak Electrical Summary 71 MW Peak Evolution of Heating Plants Radio Hall Ag Bulletin Service Building Annex Charter Street Heating Plant 1958 Present Walnut Street Heating Plant 1975 Present West Campus Cogeneration Plant 2005 Present Infrastructure Requirements 4

5 Evolution of Heating Plants Main Campus Radio Hall Evolution of Heating Plants Agriculture Campus Ag Bulletin Infrastructure Requirements 5

6 Evolution of Heating Plants Campus Aerial, ca Evolution of Heating Plants Central Heating Plant Service Building Annex Infrastructure Requirements 6

7 Evolution of Heating Plants Present Configuration West Campus Cogeneration Facility (WCCF) Walnut Street Heating Plant (WSHP) Charter Street Heating Plant (CSHP) Evolution of Heating Plants Present Configuration West Campus Cogeneration Facility (WCCF) Miles Walkable Tunnel Steam Pits? Miles of Inaccessible Box Conduits Walnut Street Heating Plant (WSHP) Charter Street Heating Plant (CSHP) Infrastructure Requirements 7

8 CSHP Plant History Constructed in 1958 Three 100,000 PPH Spreader Stoker Boilers Manufactured in 1953, Purchased Second Hand From Hudson Motors One 200,000 PPH Spreader Stoker Boiler Installed in 1964 One 300,000 PPH Gas/Oil Boiler Installed in 1970 Baghouse Constructed in 1985 Chilled Water Plant Building Additions in 1965 & MW Back Pressure Steam T/G Installed in 1995 CSHP Legal History Sierra Club Files Open Records Request in 2006 Sierra Club Indicates Filing of Lawsuit in December 2006 Sierra Club Files Lawsuit in May 2007 On November 7, 2007, the US District Court for Western District of Wisconsin Issued a Decision Finding That Three of Five Projects Between 1996 and 2004 Violated the Clean Air Act s NSR Provisions Infrastructure Requirements 8

9 CSHP Legal History US District Court for Western District of Wisconsin Findings Routine Maintenance, Repair or Replacement (RMRR) Nature and Extent Findings Project 1 Description Boiler 4 Rear Wall Replacement (73 Waterwall Tubes and Casing) Duration (Days) 45 Purpose Frequency Cost Maintain Pressure Integrity One or Two Times in Boiler Life, Not Routine RMRR Like-Kind Applicable CAA Replacement Test Modification $97,300 Yes N/A N/A No 2 Boiler 4 Side Wall Replacement (67 Waterwall Tubes and Casing) <45 Two or Three Increase Times in Availability and Boiler Life, Reliability Not Routine $77,000 No Yes Actual to Projected Actual No 3 Boiler 1, 2 and 3 Economizer Replacement 183 Increase Two Times in Availability and Boiler Life, $788,899 No No Reliability Not Routine Actual to Potential Yes (1) 4 5 Boiler 1 Stoker Feeder Replacement Boiler 4 Stoker Feeder Replacement and Boiler 1, 2 and 3 Generating Bank/ Superheater Replacement (9 mo.) Increase Boiler Two Times in Efficiency, Boiler Life, Availability and Not Routine Reliability Increase Boiler Efficiency, Productivity, Availability and Reliability $90,700 No No Two Times in Boiler Life, $1,712,348 No No Not Routine Actual to Potential Actual to Potential Yes (1) Yes (1) (1) Modified without preconstruction PSD permit so CSHP is subject to best available control technology (BACT) and must apply for revised operating permit. CSHP Legal History Sierra Club Files Open Records Request in 2006 Sierra Club Indicates Filing of Lawsuit in December 2006 Sierra Club Files Lawsuit in May 2007 On November 7, 2007, the US District Court for Western District of Wisconsin Issued a Decision Finding That Three of Five Projects Between 1996 and 2004 Violated the Clean Air Act s NSR Provisions On November 21, 2007, Sierra Club and State of Wisconsin Announce a Consent Decree to Transition Charter Street and 12 Other Coal Burning Facilities 15% Coal Reduction at CSHP Beginning 1/1/08 Feasibility Study for CSHP and CHPP By 7/2008 Lookback Study for 12 Other Coal Burning Facilities By 12/2008 (Eight Univ. of Wisconsin Institutions) Infrastructure Requirements 9

10 CSHP Comprehensive Heating Plant Study, July 2008 Four Options Analyzed Option 1 BACT on Existing Coal Boilers, New Gas Boiler Option 2 Integrated Gasification Combined Cycle Including Six Gasifiers and Two 350,000 PPH Syngas Fired Boilers Option 3 Two 350,000 PPH Gas/Oil Boilers Option 4 Two 350,000 PPH Hybrid Biomass CFB Boilers Notes: - Options 2, 3 and 4 Retire Existing Coal Boilers and Include Back Pressure Steam Turbine Cogeneration - Options 2 and 4 Capable of Burning Biomass and Fossil Fuels Infrastructure Requirements 10

11 Original Project Scope Two 225,000 PPH Packaged Gas/Oil Boilers One 350,000 PPH Biomass Boiler w/aqcs and Solid Fuel Handling Offsite Rail and Bike Path 20 MW Back Pressure Steam Turbine Cogeneration Balance of Plant Upgrades Decommissioning of All Four Coal Fired Boilers $250.6 Million Project Cost Infrastructure Requirements 11

12 Concept Diagrams 2010 Conceptual Concept Diagrams Infrastructure Requirements 12

13 Project Budget (Enumerated at $250,600,000) Phase A Packaged Boilers Phase B Biomass Boiler, AQCS and Solid Fuel Handling Phase C Offsite Rail and Bike Path Phase D Steam Turbine Generator Phase E Balance of Plant Overhead and Contractor Fee Owners Costs $ 20,000, ,600,000 4,400,000 12,200,000 36,000,000 16,000, ,200,000 50,400,000 Total Project Cost 250,600,000 Infrastructure Requirements 13

14 Original Project Scope Two 225,000 PPH Packaged Gas/Oil Boilers One 350,000 PPH Biomass Boiler w/aqcs and Solid Fuel Handling Offsite Rail and Bike Path 20 MW Back Pressure Steam Turbine Cogeneration Balance of Plant Upgrades Decommissioning of All Four Coal Fired Boilers $250.6 Million Project Cost Revised Project Scope Four Two 225,000 PPH Packaged Gas/Oil Boilers One 350,000 PPH Biomass Boiler w/aqcs and Solid Fuel Handling Offsite Rail and Bike Path 20 MW Back Pressure Steam Turbine Cogeneration Balance of Plant Upgrades Decommissioning of All Four Coal Fired Boilers $ Million Project Cost Infrastructure Requirements 14

15 November 2010 February 2011 Infrastructure Requirements 15

16 May 2011 July 2011 Infrastructure Requirements 16

17 July 2011 October 2011 Infrastructure Requirements 17

18 January 2012 February 2012 Infrastructure Requirements 18

19 March 2012 April 2012 Infrastructure Requirements 19

20 May 2012 May 2012 Infrastructure Requirements 20

21 May 2012 August 2012 Infrastructure Requirements 21

22 September 2012 Plant Dispatching MG&E Sp 3 Infrastructure Requirements 22

23 Plant Dispatching MG&E Sp 3 Generation Credit $ per kw per Day Special Terms & Provisions UW Owns a Share of WCCF (100% Chilled Water, 25% Thermal) WCCF Generators are Operating, Chillers Receive Station Service, No Demand WCCF Off (Available), On Peak, 8,500 Btu/kWh Heat Rate (Daily or FOM Gas) WCCF Off (Available), Off Peak, Sp 3, No Demand WCCF Off (Not Available), Real Time LMP Plus 10% Plant Dispatching MG&E LS 1 Infrastructure Requirements 23

24 Plant Dispatching MG&E LS 1 + IGD 1 Distribution ($0.0343/Therm) Plant Dispatching Cooling Season Dispatch Order (Current) WCCF (1) 20,000 Tons (Electric) No Demand CSHP 26,000 Tons (Steam) + Cogeneration WSHP 9,000 Tons (Steam) WSHP 11,000 Tons (Electric) Plus Demand Notes: (1) In 2015, an additional 10,000 tons will be available at WCCF. This capacity is subject to demand charges. Infrastructure Requirements 24

25 Plant Dispatching Heating Season Dispatch Order (Current) Firm Capacity (Unaffected by Electric Blips ) CSHP (1) 300,000 PPH + Cogeneration WCCF (2) 200,000 PPH (15% Dispatch Benefit) WCCF (3) 200,000 PPH (15% Dispatch Benefit) Non Firm Capacity (Electric Blips Can Cause Boiler Trips) WSHP/CSHP 1,050,000 PPH Notes: (1) In 2014, an additional 450,000 PPH of firm capacity will be available at CSHP (2) UW is responsible for uneconomic dispatch costs when WCCF is not selected by MISO (<25 MW) (3) UW takes additional steam when WCCF is selected by MISO Plant Dispatching MG&E Sp 3 MG&E Proposed 2013 Rate Case Current Infrastructure Requirements 25

26 Plant Dispatching Cooling Season Dispatch Order (Future?) WCCF (1) 20,000 Tons (Electric) No Demand WCCF 10,000 Tons (Electric) Plus Demand WSHP 11,000 Tons (Electric) Plus Demand CSHP 26,000 Tons (Steam) + Cogeneration? WSHP 9,000 Tons (Steam) Heating Season Dispatch Order (Future?) Same as Previous Questions Infrastructure Requirements 26