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Air Force Center for Engineering and the Environment Massachusetts Military Reservation MA Wind Working Group 06 Oct 2011. Rose H. Forbes, P.E. AFCEE/MMR. Primarily PCE, TCE, and EDB Concentrations generally < 1 mg/L Plumes are typically deep (>100 ft) and thick (>100 ft)
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Air Force Center for Engineering and the Environment Massachusetts Military Reservation MA Wind Working Group 06 Oct 2011 Rose H. Forbes, P.E. AFCEE/MMR
Primarily PCE, TCE, and EDB • Concentrations generally < 1 mg/L • Plumes are typically deep (>100 ft) and thick (>100 ft) • 9 treatment plants treating 10.3 MGD (down from 17.8 MGD) • > 27 miles of pipeline • > 100 EWs and RWs • > 3,000 MWs
Optimization & SustainabilityBetter, Cheaper, Faster Cleanup • Carbon • Well Maintenance • Labor • Energy/Fuel • Sampling • Drilling • Regulations • Reporting • Alternative Technologies
Energy Optimization • Wellfield optimization • Use of passive diffusion bag sampling • Use of direct push rig vs larger sonic/auger rig • On site O&M/well maintenance • Installation of VFDs and premium efficiency motors • Elimination of booster pumps and pump motor downsizing • Replaced sodium vapor overhead lighting • Use of bio-diesel, soy based hydraulic fluid • Reduction in propane use • Installation of low-wattage heaters • Misc energy (motion sensors, lighting replacement, programmable thermostats, LED exit lighting, new windows, etc.) • Signed up with the load reduction program (demand response program) • Evaluated utility rate structures
Wind Turbine - Energy Optimization • Expected to produce ~ 3,810 MWh annually based on 29% capacity factor (P50); ~ 3377 MWh annually based on 25.7% (P50) • Annual load from treatment systems in 2007 ~ 12,300 MWh; in 2011 ~10,862 MWh • Expected to generate 25-30% of AFCEE’s total electrical requirement (>$2M in 2009; $1.7 M in 2011) • Expected to reduce ~25-30% air emissions • Payback originally anticipated in 6-8 years (RECs/O&M); working on a better ROI/SROI
Wind Turbine Costs • Constructability Assessment/Environmental Assessment (CH2M Hill) - ~ $400,000 • Construction contract awarded in Sep 2007 (ECC), $4.87M (includes O&M contract for two years) • $5000 for Safety Training • $29,900 per year for two years (FLAG O&M sub - 2 maintenance events per years + warranty + availability guarantee) • $20,000 for website development • $2700 for blade inspection (year 1); $2800 for blade inspection (year 2) • Title II Services/Oversight (CH2M Hill) - $150,000 • NSTAR Interconnection/Witness Test Costs - $53,858
25 Jan – 23 Feb 2011 $573,871: 02 Dec 2009-25 Jul 2011 (+ $60,000 availability guarantee for first year)
Wind Turbine II • 2 new GE 1.5-77 wind turbines in northern part of MMR • Constructability Assessment/EA (CH2M Hill) - $462,284 • Construction Contract (ECC) + one year O&M = $9.4M • Title II Oversight/Environmental Surveys - $340,994.82 • Nstar Costs $272,000
Progress To-Date • Completed Constructability Assessment [Basis of Design, Economic Analyses, Environmental Assessment (EA)] • EA FONSI signed in Nov 2010 • Submitted Interconnection application to NSTAR • FAA studies approved • PAVE PAWS evaluation approved • Coordination with other agencies and community completed • EMC/SAC/CAC, USFWS , MA NHESP, MHC/BHC, THPO, MA FWS, MMRCT/SMB, newsreleases • Awarded construction project in Sep 2010 to ECC ($9.4M) • Initial clearing of two turbine sites in Oct/Nov 2010, included turtle surveys and baseline invasive species survey • Grubbing, cut/fill and substation clearing in March/April 2011 , included Eastern Box turtle surveys • Pre- and post-construction bird/bat surveys started/continuing
Foundations ~470 yds 5000 psi concrete 47’ diameter Spread form design Completed in May 2011
Blades - Texas Length = 121.4 ft Weight = 13,900 lbs Fiberglass construction Arrived 7 Jun 2011 • Insert photo
Tower Sections - Iowa Base: 111,400 lbs; 72 ft long; 15 ft diameter at base Steel construction Arrived June/July 2011 Mid: 80,700 lbs; 85 ft long; 14 ft diameter at base Top: 62,700 lbs; 97 ft long; 11 ft diameter at base
Tower Sections (cont) Mid section hit an overpass in Indiana on 22 Jun 2011 Driver varied from permitted route Damage was cosmetic; tests/repairs conducted on site
Machine Head - Florida 126,000 lbs 12.5 ft high 29 ft long
Progress To-Date (cont.) • Both wind turbines installed late June through mid July 2011
View from Scenic Highway (across the canal)
Remaining Schedule • Substation construction to be completed in October 2011 • Wind turbine commissioning starting 11 Oct 2011 • Interconnection anticipated 15-16 Oct 2011 • Ribbon cutting event on 27 Oct 2011 as part of October Energy Awareness Month Visits to Date • Congressman Keating – 28 Jun 2011 • Environmental Business Council – 7 July 2011 • Fox News video – 21 Jul 2011 • EOEEA Secretary Sullivan – 28 Jul 2011
QUESTIONS/COMMENTS? rose.forbes@us.af.mil
Notable Issues/Lessons Learned • Communicate early and often with stakeholders • Understand net-metering, RECs, and state rules • Utility Interconnection – build in time and plan for costs • Logistics - room to haul and build (bridges, road width, corners, permits, bad drivers, Military Cargo Preference Act of 1904, etc) • Explore additional grants • Inspect the manufacturing facilities if possible • Make sure the turbine components suppliers and transportation companies are insured. • Evaluate modes of transportation (roadway, rail, barge)
Notable Issues/Lessons Learned • Construct foundation in cool weather and allow time to achieve strength • Long lead time on turbines - explore interest from manufacturers • Plan on a schedule and hold contractors to it – include liquidated damages in contracts • Plan submittals (deliverables) and have a submittal register • Use existing wind resource data and other studies if available and applicable • Evaluate warranties and O&M/service contracts in advance; build in availability guarantee • Consult experts (i.e. DOE) on funding mechanisms (EULs, ESPCs, tax credits) • Don’t plan a ribbon cutting ceremony until the turbine is up and operational • Long Haul Project – need a dedicated champion • Take photos and video
Do spare parts come with the wind turbine purchase? • Just because spare parts are new doesn’t necessarily mean they will work • Plan for technical and safety training – involve local emergency response personnel • An FAA ruling of presumed hazard is not the end of a project, it’s the beginning of negotiations • Ensure manufacturers are reputable and there are working wind turbine models in the US for several years • Select contractors who have experience with wind turbine planning and construction projects • Are anchor bolts sized correctly? Metric vs english conversions can cause problems • Provide site signage/directions to transportation companies and police details