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Dallas VA Medical CenterA CHP Case StudyDesign Build Delivery of a Combined Heat and Power (CHP) Project for a Federal Client

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Agenda

1. Introductions2. Project Overview3. Vision4. Construction Activities5. Challenges/Lessons Learned6. Q&A

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Introductions

Mike McLaughlin, PEVice President of Engineering

Jeff GunlicksProject Manager

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Project Overview

Dallas VA Medical Center• The referral center for VA North Texas Health Care System• A major teaching and medical research center.• An 84 acre campus less than 10 miles south of Dallas• Providing a wide range of medical specialties • Includes 544 beds and over 1 million sf of healthcare space

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Project Scope• Add a 4.6 MW natural gas fired turbine to an existing

central energy plant.• Replace an existing steam boiler with a dual fuel fired Heat

Recovery Steam Generator (HRSG) to replace an existing steam boiler.

• Integrate electricity into the existing 11MW usage.

Existing Central Utility Plant

Turbine Yard

Electrical Support Building

Project Overview

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What were the project goals?• Reducing operating costs and saving energy • Leveraging renewable energy and improve “Green” footprint• Energy Security

Why was CHP chosen? • Consistent demand for power and heat.• Integrated well with existing infrastructure• Improved energy independence

Where did the owner start? • Feasibility study that assessed the economical, technical and

funding options.• Investigation included Biodiesel, Landfill Gas and Biomass and

conventional (natural gas)

Project Vision

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Power Plant Boiler Plant

45%Efficient

Traditional SystemPower Heat

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Generator Heat Recovery

80%Efficient

Combined SystemPower Heat

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Gas fired engines½ – 2.5 MW

Micro Turbines ½ - 1 MW

Gas Turbines5 – 50 MW

Heating Water180F-220F

Steam

25,000lbs/hr

400,000 lbs/hr

Power Heat

Combined Heat & Power

Dallas VA

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Air Inlet Filter

Gas Turbine

Generator

Diverter Valve

Bypass Duct Heat Recovery

Steam Generator

Combined Heat & Power

Turbine Heat Recovery

Power Heat

Supplementary Burner

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Supplementary Burner

Heat Recovery

Steam Generator

Combined Heat & Power

Heat Recovery

HeatHeat Recovery Steam GeneratorA custom piece of equipment design and fabricated to meet the project requirements• Essentially a large water tube boiler using

turbine exhaust heat as heat source

Actual Dallas VAMC HRSG during hydrostatic pressure test

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Aug 2011: Proposal Submitted

Dec 2013: Target Turnover

Project Schedule

2011 2012 2013

DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR

CONTRACT SIGNED

PURCHASE TURBINE

PURHCAS

E HRSG

DRAWING

S COMPLET

E

DRAWING

S ISSUED

FOR

CONS

TRCTUION

CONSTTRUCTION

STARTS

TUBRINE DELIVERED

CONSTRUCTION

COMPLET

E

DESIGN CONSTRUCTION

Dec 2013: NG Pipeline Complete

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CHP Construction

Considerations: • Access to site• Space for cranes to set up

TurbineEquipment Delivery & Rigging:

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CHP ConstructionHRSGEquipment Delivery & Rigging:

Considerations: • Access to site• Space for cranes to set up• Size of doors in facility

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CHP Construction

Considerations: • Access to site• Space for cranes to set up

NG CompressorEquipment Delivery & Rigging:

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CHP ConstructionSite Construction:

Considerations: • Accessibility• Noise & Emissions• Proximity to Utilities

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Inlet Air Chilling Coils

Generator and Turbine (Inside Enclosure)

Turbine exhaust

CHP ConstructionSite Construction:

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Fuel Train

Exhaustfrom Turbine

Water Tube Boiler

Economizer

Steam ConnectionMain Stack

CHP ConstructionSite Construction:

Duct Burner

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• Availability of Natural Gas will dictate size/cost of the Natural Gas Compressor.

• Turbine required 230 psig natural gas.

• Existing gas supply was 20 psig which would have required a 300 HP compressor.

• Government opted to contract for a dedicated 100-180 psig natural gas line which dropped NG Compressor to 100 HP saving significant energy

• Start up currently waiting on completion of NG line.

CHP ConstructionNatural Gas Supply:

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1. Construction in an operating Central Energy Plant• Shut-downs/high risk operations: Hot tap, Electrical tie-ins

2. Working closely with the end-user throughout the duration of the project facilitated:

CHP ConstructionOther Considerations:

• Deliver the owner products that meet their needs (example: sight glass change out).

• Facility operators become familiar with equipment, and manufacturers representatives.

• RFI’s answered quickly with design-build delivery and access to end user.

• Extensive training at facility turnover for the operators.

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3. Manufacturers Representatives are vital to the effort• Coordination is critical• Expertise is invaluable

4. Planning for Long Lead Items• Production of Shop Drawing• Payment Schedule and Financing

5. Allow for innovation and design flexibility (design-build):• Alternative Solutions within the contractual requirements• Improved performance with cost savings

CHP ConstructionOther Considerations:

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SummaryBenefits:• Improved energy efficiency• Energy Independence• Opportunities to leverage renewable energy sources• Environmental Stewardship

Options:• Available for systems from ½ MW to 50+ MW• Heat is available as heating hot water or steam• Systems can utilize packaged or custom equipment

Unique Considerations:• Design to best match your application• Construction offers different challenges that traditional construction.• Financing and Utility Rebates are commonly available.

Select qualified partners to and contract delivery methods

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Questions