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P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 01.DOC 93009 - Page 1 of 15
Above: Entrance of Port Colborne General Hospital, Port Colborne, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993)
In 1993 Marsh Energy Inc. was awarded a turnkey contract by the Port Colborne General Hospital to design, build, operate and maintain the 2nd hospital cogeneration system in Ontario utilizing a natural gas reciprocating engine-generator with steam heat recovery.
The system prime-mover is a Caterpillar Model 3306 natural gas fuelled reciprocating engine-generator set, producing 150 kWe of load displacement electricity (no export), approximately 240 lbs/hr of steam at 125 psig from the exhaust heat recovery steam generator, and about 165 kWth of hot water from the oil cooler and jacket water cooling circuits. Heat recovery was not incorporated for the aftercooler circuit.
Under normal operation the plant is unmanned.
The engine-generator set was located in an acoustically separated room, adjacent the boiler plant in the basement level, and next to the exhaust heat recovery steam generator (HRSG), (photos, right & below-right).
To achieve the low NOX emission levels required for the site, the system had to be equipped with a catalytic convertor and special “Altronic” air-fuel ratio controller, which tuned the engine for “rich-burn” operation.
To minimize noise transmission, the combustion and ventilation air inlet opening as well as the ventilation air outlet where fitted with specially designed silencers. Engine exhaust piped to the HRSG was exhausted through unused stack for the decommissioned boiler, (photo, below-left).
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Services: ( Provided by: Vito Mike Casola, P.Eng., Engineering Manager, Marsh Energy Inc. ) • Verification of Project Feasibility / Economic Analysis, • Detailed Engineering Design and Drafting, • Procurement of all Major and Auxiliary Equipment, • Preparation of Contract Documents and Contract Administration, • Project Management and Construction Supervision, • Startup / Commissioning and Operation / Maintenance, • Monthly Operational Reports.
Above: CAT 3306 genset, genset power & control panel, and Vaporphase HRSG.
Above: Outdoor view of cogen room, ventilation & combustion air inlet silencer,
ventilation outlet damper, and genset cooling circuit piping to remote roof-mounted heat dump radiator.
Above: Skid mounted genset (CAT 3306) with heat recovery circuit piping and
pumps (P-1 & P-6) to HX-1, and natural gas train.
CAT3306
GENSET 150 kWe
HRSG (125 psig)
Genset Exhaust
Stack
PORT COLBORNE GENERAL HOSPITAL
Genset Cooling Circuit Piping toRoof Mounted Heat Dump Radiator
Cogen Room
CAT 3306
HX-1
P-6
P-1
Ventilation Air Outlet Damper(silencer inside cogen room)
Ventilation & Combustion Air Inlet Silencer
Genset Exhaust Inlet Outlet
VentilationSilencer
Power & Control Panel
Exhaust Bypass
Ventilation &Combustion
Air Inlet Motorized Dampers
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 02.DOC 93009 - Page 2 of 15
Port Colborne General Hospital Port Colborne, Ontario
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont…Prime Mover Location and Ventilation Air System:
Service Provider: Marsh Energy Inc., Burlington, Ontario. An area previously occupied by a decommissioned steam boiler that was removed provided a suitable location to house the cogen system. The space was large enough to accommodate the skid mounted genset, the HRSG and a storage tank for preheating laundry domestic water.
Storage Room (previously a boiler room) sited for the new cogeneration system.
Pre-Construction: Outlining limits of new cogen room and major equipment.
Engine Exhaust Heat Recovery Steam Generator (HRSG).
Cogen Room Ventilation Air Opening, and Cooling Circuit Piping to Dump Radiator.
Installation of ventilation / combustion Variable Speed Ventilation Fan air inlet silencer in existing opening.
Cogen System Installation: Placement of skid mounted genset and HRSG.
Natural Gas Line
Outline of spaceallocated for HRSG
Ventilation
Air Outlet Opening
HRSG
VentilationAir Inlet Opening
HRSG
Cogen Room Wall Outline
Cogen Room Wall Outline
Genset
Cogen Room
Cogen Room
Boiler Room
Elec. Room
Natural Gas Line
Variable Speed Ventilation Fan
HRSG
VentilationAir Inlet Opening
Cogen Room
Cogen Room
Existing window usedas opening for outlet of
cogen room ventilation air
Cogen Room
Cogen Room
SilencerElbow
Vibration Isolation Springs
Genset Exhaust
Stack
GensetExhaust
Stack
Existing boiler combustion air opening used for inlet of cogen combustion air and cogen room ventilation air. Cogen Cooling
Circuit Piping to Dump Radiator
CAT3306
GENSET 150 kWe
Cogen Cooling Circuit Piping to Dump Radiator
Ventilation & Combustion Air Inlet Silencer
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 03.DOC 93009 - Page 3 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Prime Mover – Skid Mounted Engine-Generator Set:
At the heart of the cogeneration system is the prime mover; a 150 kWe Caterpillar 3306 natural gas spark-ignited reciprocating engine generator set (genset).
The genset was equipped with hot water heat recovery for the Oil & Jacket Water cooling circuit; the High Temperature Cooling Circuit (HTCC). Heat from the HTCC is transferred to the building hot water heating (HWH) system via a plate-frame heat exchanger (HX-1).
Pump P-1 pulls hot water from the HWH system supply header and circulates it through HX-1 to capture thermal energy from the genset HTCC and returns it back to the HWH system return header. The recovered heat is utilized by the building heating system, to preheat domestic hot water for general hospital use and to preheat laundry water. Energy utilization is measured by temperature differential and flow, via a turbine flow meter.
Left/Right: Skid mounted genset, cooling circuit piping to HX-1/radiator, and gas train.
To achieve the low NOx emission levels required for the site, the system had to be equipped with a catalytic convertor and special “Altronic” air-fuel ratio controller, (photo, left), which tuned the engine for “rich-burn” operation.
Left: Skid mounted genset, HX-1, cooling circuit piping to HX-1/radiator, engine exhaust to catalytic converter, Altronic air/fuel ratio controller mounted on the side of the genset control panel.
Natural Gas Train
Ventilation Air Outlet Silencer
Genset
Catalytic Converter
Genset Exhaust
Cogen Cooling Circuit Piping to Dump Radiator:
LTCC, HTCC, & Expansion Lines
Starting Batteries
Genset Exhaust
Genset Power & Control Panel
HX-1
P-1
P-6
HX-1
P-6
P-1
Genset
Fan
HX-
1
Genset
Genset
P-1
Starting Batteries
Starting Batteries
VentilationAir Outlet Silencer
Natural Gas Train
Genset Power & Control Panel
Turbine Flow Meter & Manual Bypass
Cogen Cooling Circuit Piping to Dump Radiator
Vibration Spring
Altronic
Genset Cooling Circuit Piping to Remote Heat
Dump Radiator
HTCCto
Rad
HTC
C to
Rad
Thermostatic3-way
Mixing Valve
LTCCto
Rad
LTCC to
Rad
HTCC
HTCC
HTCC
from
Rad
LT
CC fr
om R
ad
LTCC
to R
ad
HWH-R
Expa
nsion
line
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 04.DOC 93009 - Page 4 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Electrical Power & Control Panel & Other Electrical Equipment
Electrical equipment located inside the cogen room includes the genset power & control panel (photos right), and genset battery charger (photo bottom-right). The generator power & control panel includes annunciation lights to indicate trouble and warnings. Also included is a generator control switch and control dials / buttons (photo right-middle). The genset control switch allows for manual and auto operation. Other dials and buttons (left to right in photo) include a voltage adjust dial, an alarm accept button, an emergency stop button, a lamp test button, a frequency adjust dial, and a load set dial.
An “Altronic” Air/Fuel Ratio Controller installed on the side of the Control Panel (photos bottom-left & bottom-middle), along with a catalytic convertor limits cogen system NOX emission levels to levels required for the site.
The utility interface/sensing panel is located in the main electrical room and includes double (redundant) utility grade protection relays (below).
Genset Power & Control Panel Generator Motorized Breaker: 52-G
Above: Utility Interface/Sensing Panel (Inside Electrical Room)
Above: Altronic Air/Fuel Ratio Controller installed on Cogen Power & Control Panel
Above: Battery Charger
Battery Charger
Genset Power & Control Panel
Generator Breaker
Annunciation Lights
Genset Synchronization
Annunciation lights
Engine control switches and buttons
Utility Interface / Sensing Panel
Ventilation Air Outlet Silencer
Elbow
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 05.DOC 93009 - Page 5 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont…
Auxiliary Equipment Electrical Motor Control Centre (MCC)
The cogen system auxiliary equipment is powered through various motor control centers located inside the cogen room.
The remote heat dump radiator fans are powered through a disconnect switch and a fan motor starter/controller panel (photo, right & middle-right).
The system circulating pumps are powered through a pump motor control center (photo, middle-left & bottom-left).
The cogen room variable speed ventilation fan, (photo, right), is powered through a fan motor starter panel and controlled by a separate variable speed controller (photo, middle-left & bottom-right).
Auxiliaries: Remote Heat Dump Radiator Fan Starter / Controller.
Auxiliaries MCC: Pumps MCC, Ventilation Fan Starter & Variable Speed Controller.
Auxiliaries: Remote Heat Dump Radiator Fan Starter / Controller.
Auxiliaries MCC: Cogeneration System Pumps MCC.
Auxiliaries: Ventilation Fan Starter & Variable Speed Controller.
Ventilation Fan Starter
Motor Control Centre Auxiliaries – Auxiliary Equipment
RemoteHeat Dump Radiator
Fan Starter / Controller Panel
PowerDisconnect
Switch
Variable Speed
Ventilation Fan
HRSG
Remote Heat Dump Radiator
Fan Starter / Controller
Auxiliaries MCC
HX-1 Circ. Pump
P-1
HX-2 Circ. Pump
P-2
Feedwater Pump P-4
Laundry Preheat Pump
P-3
Hot Water Preheat Pump
P-5
Jacket Water Preheat Pump
P-6
Ventilation Fan Variable Speed
Controller
Exhaust to Stack
125
psig
HR
SG s
team
sup
ply
to h
eade
r
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 06.DOC 93009 - Page 6 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont…
Engine Exhaust Heat Recovery via Heat Recovery Steam Generator:
Thermal energy is recovered from the engine exhaust as high pressure steam. The Heat Recovery Steam Generator (HRSG), located directly adjacent to the engine-generator set inside the cogen room, generates approximately 240 lbs/hr of steam at 125 psig which is supplied to the main steam header. A backpressure steam valve only releases enough steam to maintain the supply pressure at approximately 125 psig.
During periods of low steam usage, below the output of the HRSG, steam pressure rises and excess steam blows off through an excess steam blowoff valve, to maintain steam pressure at 135 psig.
Above: CAT 3306 genset, genset power & control panel, and Vaporphase HRSG.
Above: HRSG, Genset Exhaust Piping, Feedwater Supply and Steam Outlet.
Above: HRSG Steam Supply, Backpressure Valve, Excess Steam Blowoff Valve.
Above: HRSG Steam Supply, Backpressure Valve, Excess Steam Blowoff Valve.
Above: HRSG Steam Backpressure Valve.
HRSG (125 psig)
CAT 3306
Genset Exhaust Inlet Outlet
VentilationSilencer
Power & Control Panel
Exhaust Bypass
HRSG PneumaticFeedwater Valve
HRSG
Boiler Blowdown Line
Water Level Controller
Feedwater Connection
Backpressure Steam Valve(Set at 125 psig) Excess Steam Blowoff Valve
(Set at 135 psig) Exhaust Bypass
125
psig
HR
SG s
team
sup
ply
to h
eade
r
Exhaust to Stack
HRSG Pneumatic Feedwater Valve & manual bypass
Clorius Boiler FeedwaterMagnetic Flow Meter
& Manual Bypass
125
psig
HR
SG S
team
Sup
ply
Steam Header
Backpressure Steam Valve(Set at 125 psig) Excess Steam Blowoff Valve
(Set at 135 psig)
HR
SG S
team
Sup
ply
Steam Header
HRSG Steam Supply
Backpressure Steam Valve
(Set at 125 psig)
HWH-R(Return)
HWH-S(Supply)
Steam Header
Cogen HWH Flow Meter &
Manual Bypass
HWH-S
HWH-R
HWH-R
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 07.DOC 93009 - Page 7 of 14
Port Colborne General Hospital Port Colborne, Ontario
Project Description:
Service Provider: Marsh Energy Inc., Burlington, Ontario.
2nd Hospital Cogeneration System in Ontario (1993), cont… Laundry Water Preheat / Storage and Domestic Hot Water:
Cogen Room: Laundry Water Preheat Station.
Thermal energy from the cogen system’s Jacket Water & Oil Cooler circuits is recovered and transferred to the building’s hot water heating (HWH) system, via heat exchanger HX-1. This cogen HWH is then utilized to heat both domestic hot water (DHW) and laundry water. Hot water for the hospital laundry system is preheated by the cogen HWH system, via a double-wall plate-frame heat exchanger (HX-2). Makeup domestic cold water (DCW) enters the tank, where Pump (P-3) circulates water from the storage tank to the heat exchanger (HX-2) and back the tank to preheat the water which supplies the main laundry hot water storage tank. Left: View of Laundry Water Preheat
Station inside Cogen Room. Right: Laundry Water Preheat Station,
including 100 gallon preheat storage tank, heat exchanger (HX-2) and circulation pumps (P-2 & P-3).
Laundry Water Preheat Tank, HX-2, P-2 & P-3.
Hospital DHW was previously heated by steam via shell & tube heat exchangers (HX) in primary and secondary storage tanks. The primary DHW storage tank was converted to preheat domestic water.The heat exchanger in Tank No. 1 was converted to utilize cogen HWH. Pump (P-5) circulates cogen HWH supply water to the existing heat exchanger (HX) and temperature in the tank is controlled via a 3-way thermostatic mixing valve. Left: Existing primary DHW Storage
Tank No. 1, heat exchanger (converted to utilize HWH), circulation pump (P-5), and thermostatic 3-way mixing valve.
Right: View of existing Primary DHW
Storage Tank No.1 & Secondary Storage Tank No.2, circulation pump (P-5), and mixing valve.
HRSG
Excess Steam Blowoff
New 100 Gallon
Laundry Water
Preheat Storage
Tank
Existing Primary DHW Storage
Tank No.1 converted to
preheat DHW
HX
P-2
HX-2
P-6
Genset
P-5
Exhaust to Stack
P-3
P-3
P-2 Laundry Water
Preheat Storage
Tank
P-5
HX
Thermostatic 3-way
Mixing Valve
Thermostatic 3-way
Mixing Valve
DCW Makeup
Preheated DHW Supply To Laundry
Storage Tank
HR
SG B
oile
r Fee
dwat
er L
ine
Cogen HWH
Return
Cogen HWH
Supply
CogenHWH
Supply
Cogen HWH
Return
Existing Primary DHW
Storage Tank No.1 converted to preheat
DHW
ExistingSecondary
DHW Storage
Tank No.2
HX
DHW Tank No.2
P O W E R G E N y S Y S P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 08.DOC 93009 - Page 8 of 14
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Remote Heat Dump Radiator:
The engine-generator set requires adequate cooling of the low and high temperature cooling circuits in order to maintain proper operation. This is accomplished via a remote roof mounted split coil heat dump radiator.
Heat recovery was not incorporated for the genset aftercooler circuit; the Low Temperature Cooling Circuit (LTCC). All thermal energy from the LTCC is rejected to the LTCC coil (outer coil) of the heat dump radiator.
Heat recovery was incorporated for the genset oil cooler and jacket water circuits; the High Temperature Cooling Circuit (HTCC). Thermal energy not utilized within the building hot water heating system is diverted to the HTCC coil (inner coil) of the heat dump radiator where it is rejected.
Above: View of the remote heat dump radiator, and connecting piping / conduits.
Above: Roof mounted remote Heat Dump Radiator & piping to cogen room.
Above: Heat dump radiator - coils, expansion tanks, variable speed fan & silencers.
Above: Heat dump radiator - coils, expansion tanks, variable speed fan & silencers.
Above: Piping & conduits to radiator. Above: Expansion Tank & Low Level Alarm.
Remote Heat Dump
Radiator
2 ½” Cogen HTCC Piping (Glycol/Water) 1” Expansion Lines (Glycol/Water) 1 ½” Cogen LTCC Piping (Glycol/Water) Electrical Conduits (Power & Controls) Cogen Room Ventilation Outlet Damper
Radiator Cooling Coils:Outer - LTCCInner - HTCC
Remote Heat Dump
Radiator Remote
Heat DumpRadiator
1” Expansion Lines
ExpansionTank
ExpansionTanks
DischargeSilencer
Inlet Silencer FAN
Inner Coil HTCC
Outer Coil LTCC
1 ½” Cogen LTCC Piping (Glycol/Water) 2 ½” Cogen HTCC Piping (Glycol/Water)
Expansion Tank
Low Level Alarm Switch
Power disconnect box
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 09.DOC 93009 - Page 9 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-1: Mechanical Schematic: Mechanical Schematic of Cogeneration System interconnection to existing Heating Plant.
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 10.DOC 93009 - Page 10 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-3: Mechanical Demolition and Ventilation Layout: Mechanical Demolition Work and Layout of new Cogen Room Ventilation System.
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 11.DOC 93009 - Page 11 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-6: Mechanical North Elevation: Mechanical - North Wall Elevation.
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 12.DOC 93009 - Page 12 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-7: Mechanical Sections: Mechanical Sections – Inside New Cogen Room.
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 13.DOC 93009 - Page 13 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-8: Roof Mounted Heat Dump Radiator – Layout and Details: Mechanical Layout of Roof Mounted Remote Heat Dump Radiator.
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 14.DOC 93009 - Page 14 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing P&I-1: Remote Monitoring P&I: Process and Instrumentation Drawing for Remote Monitoring / Datalogging System.
P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N
File: PI-93009 - Port Colborne Hospital Cogen 15.DOC 93009 - Page 15 of 15
Port Colborne General Hospital Port Colborne, Ontario
Service Provider: Marsh Energy Inc., Burlington, Ontario.
Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing E-3: Electrical Layout – Plan: Electrical Layout Drawing.