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Lansing Board of Water & Light REO Town Headquarters & Cogeneration Plant

Lansing Board of Water & Light REO Town Headquarters & Cogeneration Plant. REO Town Cogeneration: Concept to Commercial Operation. Agenda. BWL Background REO Town Firsts Steam Production Study & Recommendations Selecting the Design, Build, Startup and Commission team What we built

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Lansing Board of Water & Light REO Town Headquarters & Cogeneration Plant

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  1. Lansing Board of Water & LightREO Town Headquarters & Cogeneration Plant REO Town Cogeneration: Concept to Commercial Operation

  2. Agenda • BWL Background • REO Town Firsts • Steam Production Study & Recommendations • Selecting the Design, Build, Startup and Commission team • What we built • Starting Up & Commissioning your own Plant!? • Questions

  3. BWL Background • The BWL is the largest municipal utility in Michigan and is owned by the citizens of Lansing. • Largest groundwater sourced drinking water system in Michigan (54,900 Customers) • Number of electric customers • 82,823 Residential • 12,708 Commercial • 272 Industrial • Also serve the Lansing downtown district with steam heating and chilled water

  4. BWL Background (cont’d) • Major steam customers in downtown Lansing include: • GM Grand River Assembly plant • State of Michigan buildings • Cooley Law School • Lansing Comm. College • Accident Fund National HQ • Peak seasonal load of 300,000 lbs/hr of steam • Over 12 miles of steam distribution piping

  5. REO Town Firsts • First new utility power plant built in Michigan in 25 years • First power plant built by the BWL in 40 years • BWL’s first natural gas-fired electric generating plant • BWL’s first cogeneration plant • Among the cleanest and most efficient plants operating in Michigan and the US

  6. Steam Production Study • 2010 Steam Production Study identified the following: • Four stoker, coal fired boilers ranging in age from 43 to 55 years have exceeded their design life • $32 Million in capital expenditures to replace: • External skin on 3 of 4 boilers • Soot blowers • Economizer and superheater tubes • Upgrade boiler controls

  7. Steam Production Study (cont’d) • $35-$107 Million in environmental upgrades to comply with forth coming regulations • No guarantee the environmental upgrades to the Moores Park boilers will meet pending EPA regulations, resulting in a loss of $67 - $139 million investment (boiler and emissions control upgrades) • Need for additional electric generating capacity by 2017 due to aging electric units

  8. Steam Production Study Recommendations • Build a new CHP (Combined Heat & Power or Cogeneration) plant • Beneifts include: • Diversify fuel mix (mostly PRB coal) • Avoid burning 351,000 tons of coal a year • Reduce Mercury & SO2 emissions 99% • Improved efficiency • Lowers NOx emissions by 85% and CO2 by 50%

  9. Steam Production Study Recommendations (cont’d) • Help exceed the EPA goal of reducing greenhouse gases by 17% by 2020 • Major work on the Moores Park boilers could trigger New Source Review • Replace 100 MW of aging coal fired electric generation

  10. Selecting the Design, Build, Startup and Commission team • BWL Project Director and Project Manager • Hire an Owner’s Engineer • Architectural & Engineering firm to design the plant • Construction firm to build the plant.  Also had the responsibility to hire a Startup and Commissioning Team • BWL Operations staff to participate in startup and early operation of the equipment

  11. What we built • Plant specifications • (2) GE LM6000 PF/DLE units capable of 50 MW each • (2) Once Through Steam Generators (OTSG) 175 klbs/hr each • (1) Gas Fired Package Boiler 175 klbs/hr • (1) 14.4 MW topping Steam Turbine Generator • (2) 100% Reciprocating Gas Compressors • (3) 50% Boiler Feed and Condensate Pumps • (2) 100% Circulating Water Pumps • (2) 100% Aux Cooling Pumps • (2) 100% Plant Air Compressors • (3) 50% Reverse Osmosis Trains

  12. 14.4 MW Steam Turbine (Elliott/Hyundai)

  13. 175 klbs/hr package boiler (Victory Energy)

  14. Boiler Feed Pumps (Goulds) & OTSG 2 (IST)

  15. Condensate, Aux Cooling & Circulating Water Pumps

  16. Reverse Osmosis Trains (US Water)

  17. Duct Burners on OTSG 1

  18. GE LM6000 PF/DLE Gas Turbine Package(Unit 1)

  19. Mezzanine Level Deaerators and Cooling Tower Piping

  20. Starting Up & Commissioning your own Plant!? • Construction firm lost Startup and Commissioning Manager 2.5 months before Commercial Operation date • Project team elected to have the Plant Engineer assume the role of Startup and Commissioning Manager • Due to project schedule challenges, BWL supplemented the startup and commissioning team with Operators, Instrument Controls Specialists, Controls Engineer, Project Engineer, Maintenance Supervisors, Plant Manager and a Trainer.

  21. Starting Up & Commissioning your own Plant!? (cont’d) • Major equipment suppliers (ie. GE gas turbines, Boilers, Reverse Osmosis trains, etc.) commissioned their equipment with field technicians supported by the BWL team • We made it!  $182 million plant built on time and on budget with a commercial operation date of July 1, 2013.

  22. Thank you Questions? Rob Hodge Plant Manager rah1@lbwl.com

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