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Air Force Center for
Engineering and the
Environment
Massachusetts Military
Reservation
28 Mar 2012
Rose H. Forbes, P.E.
AFCEE/MMR
Federal Government and Military
Projects: Success Story, Current
Trends & Best Practices
2
Primarily PCE, TCE, and EDB Concentrations generally < 1 mg/L
Plumes are typically deep (>100 ft)
and thick (>100 ft)
9 treatment plants treating 12 MGD (down from 17.8 MGD)
> 27 miles of pipeline
> 100 EWs and RWs
> 3,000 MWs
Sustainability Evaluation
6
Wind I • Fuhrlaender 1.5 MW, 80 m hub, 77 m rotor
• Five year project; date of operation 2 Dec 09
• Expected to produce ~ 3,810 MWh annually based on 29% capacity factor (P50); ~ 3,377 MWh annually based on 25.7% (P90)
• Expected to generate 25-30% of AFCEE’s total electrical requirement (>$2M in 2009; $1.7 M in 2011)
•Actual production: see chart on next slide; capacity factor @17% for Year 1, 24% Year 2, 28% Year 3 (to date)
• Comparison of energy production to energy use: see chart on next slide
• Expected to reduce ~25-30% air emissions
• Payback originally anticipated in 6-8 years (RECs/O&M); latest ROI/SROI showing ~10 years
7
• will insert when the chart is ready
Insert Use vs Production Chart
25 Jan – 23 Feb 2011
$689,432: 02 Dec 2009-26 Dec 2011 (+ $60,000 availability guarantee for first year and meter problem)
Wind II
9
10
Wind II • Two GE 1.5 MW, 80 m hub, 77 m rotor • Two year project; date of operation 8 Nov 11
• Expected to produce ~ 7,620 MWh annually based on 29% capacity factor (P50)
• Expected to generate 50-60% of AFCEE’s total electrical requirement (>$2M in 2009; $1.7 M in 2011)
• Actual production: 3250.25 MWh to date; capacity factor @35.5%
• Expected to reduce ~25-30% air emissions
• ROI/SROI showing ~10 years
Details Wind I Wind II
Machines One Fuhrlaender 1.5 MW Two GE 1.5 MW
Hub height/rotor diameter 80 m/77 m 80 m/77 m
Total height ~390 ft ~390 ft
Startup Date (witness test) 2 Dec 2009 8 Nov 2011
Project Timeframe ~5 years ~2 years
Distance from homes 1140 ft (on base residents) 3000 ft (off base residents)
Foundation Spread form – 57’ diameter, 600 yds 5000 psi
concrete
Spread form – 47’ diameter, 470 yds 5000 psi concrete
Blades ND: 122 ft, 13,600 TX: 121.4 ft, 13,900 lbs
Tower Sections MN: 4; 41’-79’; 65,000-106,000 lbs IA: 3; 72’-97’ long; 62,700-114,000 lbs
Machine Head GE: 12.8’ high, 26.6’ long, 143,200 lbs FL: 12.5’ high, 29’ long, 126,000 lbs
Crane Manitowoc 16000; 440 ton; 315’ mast Manitowoc 16000; 440 ton; 315’ mast
Funding Type Environmental Restoration Account Environmental Restoration Account
Constructability Assessment $400,000 $462,284
Construction $4.87M (plus two years O&M) $9.43 (plus substation and one year O&M)
Utility Interconnection $53,858 (to existing 23 kV distribution) $272,000 (to new 23 kV distribution line through new
substation and then to existing 115 kV transmission line)
Title II Oversight $150,000 $341,000 (and environmental surveys)
Energy Production (startup to date) 6145 MWhr (02 Dec 09 - 14 Mar 12) 3250 MWhrs (8 Nov 11 - 14 Mar 12)
Capacity Factor Ranged from 17% in first year to 24% in second
year; 28.5% third year to date
35.5% to date
ROI 9-10 years 9-10 years
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 – can AF/DoD accept them?
• Inspect the manufacturing facilities if possible
• Make sure the turbine components suppliers and transportation companies are insured.
• Evaluate modes of transportation (roadway, rail, barge)
• Contracting: Firm Fixed Price or Cost (Best Value or Lowest Price)
• 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
Notable Issues/Lessons Learned
Notable Issues/Lessons Learned • Construct foundation in cool weather and allow time to achieve
strength • Long lead time on turbines - explore interest from manufacturers
(important on Wind I, not so much on Wind II) • Plan on a schedule and hold contractors to it – include liquidated
damages in contracts • 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, AFCESA) on funding mechanisms
(DERA, ECIP, 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 • What about O&M????
Examples of Other Projects - MMR
• PAVE PAWS wind turbines – ECIP funds, own & operate
• 102 IW (ANG – Otis) – solar PV on landfill (DLA – developer based PPA)
• The VA cemetery installed a smaller wind turbine (50 kW) on their property
• USCG uses a geothermal heating/cooling system at one of its hangars and is incorporating geothermal in a new hangar construction project
Examples of Other Projects
• USACE-Kansas City wind turbine project
• FE Warren – Cheyenne WY wind turbines
• See AFCESA website for additional projects at AF/ANG bases
• Town of Plymouth wind turbines; land lease developer based PPA
• Town of Plymouth solar PV on landfill – land lease, developer based PPA
Issues for Wind Developers • Land lease on federal property can be
complicated
• Price of solar << than wind turbine in a power purchase agreement (especially in MA)
• Utility interconnection
• AFCESA, AFCEE, USACE, DLA, GSA – get to know your toolbox of selected contractors
• Central Contractor Registration (register)
• Federal Business Opportunities
Issues for Wind Developers • Engineering Technical Letter (ETL) 11-1 (dated
30 Mar 2011): Civil Engineer Industrial Control System Information Assurance Compliance
• Contact agencies and toolbox contractors and provide company information
• DoD getting familiar with wind projects but not quite there yet
Agencies/Contacts
• Air Force Civil Engineering Support Agency (AFCESA) -AFCESAReachBackCenter@tyndall.af.mil
• Air Force Center for Engineering and the Environment (AFCEE)
http://www.afcee.lackland.af.mil/contracting/contracts.asp
• Air Force Real Property Agency (AFRPA)
http://www.safie.hq.af.mil/afrpa/index.asp
• Defense Logistics Agency
http://www.dla.mil/Pages/default.aspx
Agencies/Contacts
• US Army Corps of Engineers
• Federal Business Opportunities: https://www.fbo.gov/
• Central Contractor Registration: https://www.bpn.gov/ccr/default.aspx
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
Distance from turbine to base
housing ~ 1140 ft
Activities • Completed Constructability Assessment [Basis of Design, Economic
Analyses, Environmental Assessment (EA)]
• EA Public Comment Period; 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, news
releases
• 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
• Insert photo Length = 121.4 ft
Weight = 13,900 lbs
Fiberglass construction
Arrived 7 Jun 2011
Tower Sections - Iowa
Mid: 80,700 lbs; 85 ft long;
14 ft diameter at base
Top: 62,700 lbs; 97 ft long; 11 ft diameter at base
Base: 111,400 lbs; 72 ft long; 15 ft diameter at base Steel construction
Arrived June/July 2011
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
Under Construction
• Both wind turbines installed late June through mid July 2011
View from Scenic Highway (across the canal)
Both turbines produced a
combined total of 2173
MWhr from 04 Nov 2011 –
31 Jan 2012
View from Sagamore Bridge
Ribbon Cutting
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