Successful Combined Heat and Power Systems at Federal Sites

1. Successful Combined Heat and Power Systems at Federal Sites Presented by William (Bill) Chvala, Jr., CEM Senior Research Engineer Pacific Northwest National Laboratory william.chvala@pnl.gov

2. Executive Order 13123 “Agencies shall consider combined cooling, heat, and power when upgrading and assessing facility power needs and shall use combined cooling, heat, and power systems when life-cycle cost-effective.” - Section 401(g) Highly Efficient Systems Executive Order 13123, June 1999 CHP in the PNW and Regional Roadmap Workshop

3. US Combined Heat and Power Association “The goal of this National CHP roadmap is to add 5 GW of new CHP installations in Federal facilities by 2010.” - National CHP Roadmap, US Combined Heat and Power Association March 2001 CHP in the PNW and Regional Roadmap Workshop

4. Federal-Sector CHP Market • US Army, Construction Engineering Research Laboratories’ Study • Studied 55 DOD sites in WAPA territory • 37 of 55 sites indicate CHP cost effective • 340 MW potential CHP capacity • Savings exceed $40M per year • USCHPA calls for a national inventory of potential Federal CHP sites CHP in the PNW and Regional Roadmap Workshop

5. Navy San Diego, CA Port Hueneme, CA New London, CT Indian Head, MD Norfolk, VA Great Lakes, MI Marines Parris Island, SC Army Fort Dix, NJ Veteran Affairs San Diego, CA DOE Idaho Falls, ID Postal Service Anchorage, AK Some Existing CHP Systems at Federal Sites (FY 2001) CHP in the PNW and Regional Roadmap Workshop

6. U.S. Postal Service Mail Processing and Distribution Facility Post Office in front 1-MW CHP in back CHP in the PNW and Regional Roadmap Workshop

7. Factors Leading to CHP • Operation 24/365 • Larger emergency generator required after facility expansion • Larger fuel oil tank required • Fuel oil tank required upgrade • UPS system required upgrade • Boilers required improvement CHP in the PNW and Regional Roadmap Workshop

8. Results • Five 200-kW fuel cells by IFC provides 100% of power and heat required by USPS facility • CHP plant owned and operated by Chugach Electric Association • USPS facility saves more $800,000 over 5-1/2 year contract • Reliability improved CHP in the PNW and Regional Roadmap Workshop

9. 2001 Federal Energy Management Award CHP in the PNW and Regional Roadmap Workshop

10. The Site Management System (SMS) Makes This Special • SMS allows multi-fuel cell system to transfer between grid-parallel and grid-independent in under 4-milliseconds(1/4 cycle in a 60-Hz system) • Fast enough that the computer systems are not interrupted by the transfer • SMS developed in partnership with USPS, Chugach Electric Association, DOE, DOD, CERL, EPRI, and NRECA CHP in the PNW and Regional Roadmap Workshop

11. Boilers were not required during the winter of 2000-2001 80 hp fire-tube boilers Heat recovery system CHP in the PNW and Regional Roadmap Workshop

12. Lessons Learned Projects of this nature require “champions,” to think outside of the box, overcome barriers, and push the project through. The development of the SMS will lead to more multi-fuel cell power plants with high-speed reliability. CHP in the PNW and Regional Roadmap Workshop

13. Thank you

14. Additional Federal CHP Sites CHP in the PNW and Regional Roadmap Workshop

15. U.S. Naval Submarine Base New London Received 1997 Federal Energy Management Award CHP in the PNW and Regional Roadmap Workshop

16. Factors Leading to CHP • Contracted electric demand limit with stiff penalty • Year-round heat load • Desire to reduce operating costs • Age of existing infrastructure CHP in the PNW and Regional Roadmap Workshop

17. Special Issues • Allow for quick startup to accommodate dynamic load changes • Ability to separate generation systems to allow for main plant shut down • Ability to use alternative fuels • Limited space available • Environmental permits CHP in the PNW and Regional Roadmap Workshop

18. CHP plant 20 MW and 5 MW systems, maybe growing 5 MW combustion turbine CHP in the PNW and Regional Roadmap Workshop

19. Control room Heat recovery system 5-MW combustion turbine CHP in the PNW and Regional Roadmap Workshop

20. Results • 5-MW turbine and 50,000 pph, 300 psi boiler with duct burner • Installed in 1997 • Logged 18,000 hours in first 3 years • Recovered energy used for heat and process steam load around Base • Estimate savings of $500,000 during FY2000 CHP in the PNW and Regional Roadmap Workshop

21. One Issue • System does have some difficulty restarting when switching to an alternative fuel after long periods of operation • Cost reduction is well worth the effort • Dual-fuel capability is an important strategy to managing operating costs CHP in the PNW and Regional Roadmap Workshop

22. Lessons Learned • Carefully consider utility loads to determine type of CHP that would best fit your needs • Consult with local utility for incentives • Ensure system has multi-fuel capability • Consult with State’s Department of Environmental Protection to ensure allowance for new source siting CHP in the PNW and Regional Roadmap Workshop

23. Future Plans • Energy Board of Directors is considering the addition of another 10-MW combustion turbine CHP system CHP in the PNW and Regional Roadmap Workshop

24. Navy Medical Center, San Diego • Installed in 1985 • 3 800-kW combustion turbines • 3 heat recovery steam generators • 3 25,000 pph steam boilers • 1 800-ton single-stage absorption chiller • 2 800-ton electric centrifugal chiller • Navy considering upgrading this plant CHP in the PNW and Regional Roadmap Workshop

25. 800-kW combustion turbine CHP in the PNW and Regional Roadmap Workshop

26. 800-kW combustion turbine Heat recovery boiler CHP in the PNW and Regional Roadmap Workshop

27. Heat recovery boiler 800-kW combustion turbine CHP in the PNW and Regional Roadmap Workshop

28. Absorption chiller 25,000 pph fire-tube boilers CHP in the PNW and Regional Roadmap Workshop