it’s all about energy · 2017. 10. 17. · it’s all about energy mdc’s on-site power generaon...
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It’sAllAboutEnergyMDC’sOn-SitePowerGenera<on&Energy
Conserva<onEffortsattheHarBord,CTWPCF
NortheastResiduals&BiosolidsConferenceCromwell,CT
October13,2016
Presenta<onTopics
S MDC&WaterPollu<onControlOverview
S ElectricityUse
S DriversforHeatRecovery
S Implementa<onandResults
2
TheMetropolitanDistrict
S CharteredbytheConnec<cutGeneralAssemblyin1929S Servicesprovidedtoapproximately400,000popula<on
Ø WaterSupply–40billiongallonsin2reservoirsØ WaterTreatment–2plants,85+MGDcapacityØ WaterDistribu<on&wastewaterCollec<on
• 2,700+milesofdistribu3onandcollec3onsystempiping• 80+waterandwastewaterpumpsta3ons
Ø WastewaterTreatment–4plants,135MGDcapacityS ~530employeeswithanannualopera<ngbudgetof~
$140MS Undertaking$2.1BCleanWaterProgramtoaddressSSOs
andCSOs
3
MapofSewerServiceArea
4
WaterPollu<onControl(WPC)
S WPCoperates4treatmentfacili<esØ EastHarBord–12.5MGDØ Poquonock–5.0MGDØ RockyHill–7.5MGDØ HarBord–80MGDsecondary&30MGD
wetweather• LargestCTwastewatertreatmentplant• HWPCFaveragedailyflowis60MGD
S AllWPCfacili<esoperatecon<nuouslyØ HarBordWPCFisstaffed24/7Ø SatelliteplantsonlystaffedM-F,7:30–
4:00,withweekendplantchecksØ HarBordstaffmonitorssatelliteplantsvia
SCADAalarms
5
HarBordWPCF
HarBordLiquidTreatmentProcess
Primary
SecondaryBNR
SeasonalUVDisinfec<on
ToConnec<cutRiver
Preliminary
DynamicSeparators
WetWeatherPumpSta<on
StorageLagoon
PrimaryEffluentPumpSta<on
HighCTRiverEleva<on
PumpSta<on
LagoonOverflowChlorina<on
6
HarBordSolidsTreatmentProcess
PrimarySludge
WasteAc<vatedSludge
OutsideSolids
GravityThickeners
CentrifugeDewatering
Incinera<on
DissolvedAirFlota<onThickeners
SatellitePlants’SolidsElectricalProduc<on
Blending
Ash
Heat
SolidsProcessingChallengesS TheDistrict'sfourWPCFsproduceabout35drytonsof
sludge/dayS OperateaRegionalSolidsReceivingFacility–process
between35and50drytonsofsludge/dayfromoutsideplant:Ø Threesatellites,twobyforcemainØ CakeØ ThickenedØ LiquidØ SeptageØ 454/industrial
S Loadingsarenon-consistent,open24/7S Averagemorethan1,000transac<onspermonth
8
DistrictWideElectricityUsage
9
S Wastewatertreatmentis76%ofu<lityelectricityusageS Watertreatmentis6%
59%
6%
1%
10%
3%
3%
3%
2%
2%
1%
10%
Total2014usage:40,116,277kWh
HarBordWPCF
RockyHillWPCF
PoquonockWPCF
EastHarBordWPCF
WestHarRordWTF
Reservoir6WTF
MDCHeadquarters
WethersfieldPumpSta3on
MDCOpera3onsandTrainingFacility
NewingtonPumpSta3on
OtherFacili3es
HarBordWPCF2014usage:24,000,000kWh
HarBordWPCFElectricityCostvs.Use
10
S Increasingenergycostsdrivetheheatrecoveryproject
Onanaverageday,theHWPCFusesenoughelectricitytolightmorethan35,000one-hundredwambulbs!
HeatRecoveryTimeline
S Discussionsandconceptsaboutheatrecoverystartedinearly2000’s
S Energycostscon<nuetoincreaseS 2009FederalS<mulus–ShovelReadyGreen
InfrastructureØ CTDEEPoffersgrantsandlowinterestloans
(ARRA)Ø Projectmustbedesigned,bidandawardedby
Feb2010Ø 15monthsfromno3cetoproceedØ ProjectbidDec2009,awardedJan2010
S Construc<on2010–2013,projectcombinedwithincinera<onupgrades
S MDCtakefullcontrolJanuary2014
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InstallingElectricityProduc<onØ Heatrecoverybasicallyputanelectricalgenera<onprocessina“wide
spot”intheincineratorexhaustpipingtogenerateelectricity
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ElectricityProduc<on
13
EnergySustainabilityatHWPCFHeatRecovery
S Useheatfromincinera<ontogenerateupto40%ofourownenergy.
S Biosolidsprovidea‘green’renewablesourceofenergy
Black&Veatch3Ddesign
SiteVisitCri<calforSuccess
S NewHaven,CTcompleteddesign-buildHRprojectØ Severalissuesariseandconsistentopera3onsproveschallengingØ NewHavenstaffsharesmul3plelessonslearnedwithMDCthatare
incorporatedintoourproject• Boilerorienta3on-usever3calboilertubestominimizeashdeposit• Boilermaterials• Facilitylayoutforeaseofopera3onandmaintenance• Boilerwarmingsystemtominimizecoldendcorrosionofboilertubes• Sootblowersinstalledinsteadofsonichorns• Ashcollec3onsystemsinstalledatbodomofboilers
Ø Interconnectagreementwithelectricityprovidernearlyastart-upshow-stopper
S MDCusesNHexperiencetomakeabemerproject
14
MainComponentsS Heatrecovery&steamproduc<on
Ø Incinera3ongasintoboilersatapproximately1,200oF.Ø ExhaustleavingtheBoilersisapproximately400oFØ Twoboilers,eachproduceupto26,000lbs/hr.of400PSI
steamØ Condensaterecovery
S Electricalproduc<onØ Turbine,reduc3ongearbox&generatorØ Electricalconnec3ontoplant’smainelectricaldistribu3onØ Produceupto2MWs
S WatertreatmentØ Vitalforpeakperformance
S Automa<onØ SystemiscompletelyautomatedØ ConnectedtoplantSCADAsystem
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HeatRecovery&ElectricityProduc<on
16
Incinerators
HEAT
Boilers
STEAM
Turbine
Generator
ElectricitytoplantgridPumps
Treatedwater
Steam
SurfaceCondenser
CondensateTank
PumpsDeaeratorPumps
HeatExchangers
Pumps
WaterTreatmentSystem
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MDCWater
WaterSosenersCarbonFiltersReverseOsmosisPumps
PumpsPermeateTank
StorageTank
IonExchange/Demineralizer
Pumps
WaterTreatmentChemicals
HeatRecoveryMainSCADAScreen
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Opera<onalLessonsLearned
19
S Teamapproachworkedverywell–keytosuccessS Staffconsistency&engagement
Ø Staffengagedindesign,tes3ng,SOPsdevelopment&maintenanceS Usedprojectasopportunitytochangesolidsprocessinginto
24/7opera<on–majorplant-widebenefitsS Don’tunderes<matethetrainingschedule–it’snotanother
clarifier–20+classesS Communica<onvitalS DevelopmentofSCADAearlyinprojecthelpedtransi<onto
opera<onsS Long-termopera<ons&maintenancesupportiscri<calS Afewcri<calsparepartsarenecessary
Results?Success!
20
S Safetyrecordhasbeenoutstanding–noreportableinjuriessustainedin2+yearsofopera<on
S HWPCFstafftookoverthefacilityonJan1,2014Ø In2014produced7.6millionkWhs,valuedat~$1M!($0.13/
kWh,allin)Ø In2015produced9.7millionkWhs,valuedat~$1.3M!
SewngtheGenerator
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SewngBoilers
22
SteamBlow–CleanOutPriortoStart-Up
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SteamBlow–CleanOutPriortoStart-Up
24
WHRBuilding
25
Boilers
26
Turbine&Generator
27
WaterTreatment
28
BoilerWaterSystem
29Deaerator
CondensateTankSurfaceCondenser
ElectricalRoom
30
ControlRoom
StaffisUl<mateDriverforSuccess
S Ul<matelythepeopleinvolvedmakeitsuccessfulS Manythanksto:
Ø JeffBowers,SuperintendentØ MikeZabilansky,ProjectEngineerØ MikeMeany,Construc3onInspectorØ BruceLundie,HWPCFShikSupervisorØ JoseJurado,HWPCFCrewLeaderØ GaryDougenik,I&CTech
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EnergyEfficiencyIni<a<ves
32
S Makingourownpowerisonlypartofthesuccessstory,usinglessenergyisalsocri<cal.
S Energyefficiencyini<a<vesinclude:Ø PlantwidepowerfactorimprovementstoaddresskVAbillingØ Replace3,000Hpblowerswith1,250HpunitsØ Highefficiencypumps,VFDs&controlsinallinstancesof
construc3on(RAS,WAS,centrifugefeed,plantwater,etc.Ø CentrifugecontrolsØ InfluentpumpsatnewheadworksfacilityØ UpgradeDOcontrolsforbedernitrogenremoval(saves$onCT
DEEPNitrogenTradingprogram)andreducedenergyØ Mul3pleligh3ngefficiencyprojects
S MakemaximumuseofEversourceEnergyEfficiencyrebateprogram.Todatehavereceivednearly$2Minrebates.
S LookingintoRenewableEnergyCredits(RECs)