Well Field Remote Monitoring and Control: Case Study at Crapo Hill Landfill

Transcription

1 Well Field Remote Monitoring and Control: Case Study at Crapo Hill Landfill SWANA NJ Chapter - April 14 th, 2015 Presented by: Andrew Campanella

2 About the presenter ANDY CAMPANELLA - B.S. Electrical Eng. and Computer Science at MIT - M.S. in System Design and Management at MIT - Founder and CEO of Loci Controls, Inc. - Inventor on 32 US patents, dozens of applications - Expert in control systems, instrumentation, power systems, and electronics

3 Outline - Introduction - Typical Landfill Gas Collection Process - Remote Monitoring and Automatic Control - Case Study - Crapo Hill Landfill

4 Typical gas collection system 2 GAS COLLECTED FROM WELLS 3 GAS BURNED TO GENERATE ELECTRICITY 1 TRASH GENERATES METHANE GAS 4 ELECTRICITY SOLD TO THE GRID $$$

5 Drawbacks of typical collection system Manual surveys of well field are very labor intensive Infrequent measurement & tuning due to time/effort required Well adjustments are an art rather than a science

6 Automated well field control system

7 Installed hardware

8 Sensor Suite: CH4 CO2 O2 Temperature Pressure Flow rate

9 Set custom alarms Instantly identify problems View real time data Energy analytics

10 Control valve: Remote control 0-100% range Linearized output Solar powered

11 Control system objective Gas Extraction = Gas Generation LFG E t = LFG G t - Stable gas quality - Minimized emissions - Long term maximization of methanogenesis - Eliminates risk of underground fire

12 Gas extraction modeling Find correlations between variables at each well Express correlations between wells Add outside data (weather, etc.) Generate predictive estimates of well production at different operating points Calculate optimum operation condition for each well

13 Crapo Hill Landfill in Dartmouth, MA Landfill owner - Greater New Bedford Regional Refuse Management District Landfill Site 152 Acres Current Landfill Size - ~40 Acres Permitted Capacity 100,000 Tons/yr Waste in Place - ~2,000,000 Tons

14 Crapo Hill Landfill in Dartmouth, MA LFG-E Facility Owner Commonwealth Resource Management Corporation End User - Power sold to NSTAR Generators 4 Caterpillar 3516 Engines Generation Capacity 3.2 MW

15 Case Study Overview Want to quantify real world impact Outfit top 13 horizontal and leachate collector wells with automation system - Wells account for > 60% of total flow All wells located in active area 3 month data collection: Aug Nov 2014 Comparison against same period in 2013 and July 2014

16 Lessons learned Very strong well to well interactions! Unexpected problems with well flooding Production increased through use of automated monitoring and control

17 Well to well interactions Crapo Hill A B

18 Well to well interactions Extraction Zone A Influence of Well B on A Well A LFG A t f (x 1, x 2,...) + f (LFG B ) Influence of Well A on B Well B LFG B t f (x 1, x 2,...) + f (LFG A ) Extraction Zone B

19 Example of coupled wells Crapo Hill :48 PM 6:00 PM 7:12 PM 8:24 PM 9:36 PM 10:48 PM Methane killed from Sept 25 7pm SCFM 60 Well A Flow Rate Well B Flow Rate CH4 % Well A CH4% Well B CH4% 45 4:48 PM 6:00 PM 7:12 PM 8:24 PM 9:36 PM 10:48 PM

20 OPEN VALVE WELL A :48 PM 6:00 PM 7:12 PM 8:24 PM 9:36 PM 10:48 PM Methane killed from Sept 25 7pm SCFM 60 Example of coupled wells Crapo Hill Well A Flow Rate Well B Flow Rate CH4 % Well A CH4% Well B CH4% 45 4:48 PM 6:00 PM 7:12 PM 8:24 PM 9:36 PM 10:48 PM

21 :48 PM 6:00 PM 7:12 PM 8:24 PM 9:36 PM 10:48 PM Methane killed from Sept 25 7pm SCFM 60 Example of coupled wells Crapo Hill Well A Flow Rate Well B Flow Rate CH4 % :48 PM 6:00 PM 7:12 PM 8:24 PM 9:36 PM 10:48 PM 2 DROP IN CH4 WELL B Well A CH4% Well B CH4%

22 Lessons learned Very strong well to well interactions! Unexpected problems with well flooding Production increased through use of automated monitoring and control

23 Horizontal Well Flooding

24 Real Time Detection of Well Flooding

25 Lessons learned Very strong well to well interactions! Unexpected problems with well flooding Production increased through use of automated monitoring and control

26 0.4 Pilot results % higher power from automated wells! 0.35 Gas Extraction (million BTU/minute) Performance with Loci Baseline Performance 0.15 WEEKS 1.408E E E E E E+09

27 Total flow increase of 13.8% days engines down in days engines down in SCFM 900 AVG. 132 SCFM INCREASE DAY Sept % CH4 Sept % CH4

28 Potential for system automation More gas = more revenue Reduction of risks through continuous monitoring Underground fire or reactions Odor complaints Emissions violations Labor savings more efficient use of technician time MORE $$$ MORE GAS

29 THANK YOU! SWANA NJ Chapter - April 14 th, 2015 Andy Campanella andy@locicontrols.com Phone (585)