uw madison september 13, 2012 -...

UW‐Madison September 13, 2012

CSHP Rebuild Project and Campus Utility Infrastructure Requirements 1

Wisconsin Public Utility InstituteGas: What’s in the Pipeline?

Making the Switch to Gas: Utility Infrastructure Needs and a Case Study of a Coal‐to‐Gas Plant Conversion

Jeff Pollei, UW‐Madison

Agenda

Campus Overview and Utility Summary

Evolution of Heating Plants

CSHP Plant History

CSHP Legal History

CSHP Rebuild Project

Plant Dispatching



Founded in 1848

12 Schools/Colleges

Enrollment of 42,099

>18,500 Employees and Faculty

20.6 Million GSF on 935 Acre Main Campus (>27.0 Million Total)

University of Wisconsin Overview

Campus Overview (Before March 2012)

Walnut Street Heating Plant (WSHP)• 600,000 PPH Steam (Nat. Gas)• 11,000 Tons Chilled Water (Electric) • 9,000 Tons Chilled Water (Steam)

West Campus Cogeneration Facility (WCCF)• 400,000 PPH Steam• 20,000 Tons Chilled Water (Electric)• 100 MW Combustion T/G (Nat. Gas)• 68 MW Extraction/Condensing T/G

Charter Street Heating Plant (CSHP)• 500,000 PPH Steam (Coal)• 300,000 PPH Steam (Nat. Gas)• 26,000 Tons Chilled Water (Steam)• 9.7 MW Back Pressure T/G



Campus Overview

Campus Overview (January 2015)

Walnut Street Heating Plant (WSHP)• 600,000 PPH Steam (Nat. Gas)• 11,000 Tons Chilled Water (Electric) • 9,000 Tons Chilled Water (Steam)

West Campus Cogeneration Facility (WCCF)• 400,000 PPH Steam• 30,000 Tons Chilled Water (Electric)• 100 MW Combustion T/G (Nat. Gas)• 68 MW Extraction/Condensing T/G

Charter Street Heating Plant (CSHP)• 900,000 PPH Steam (Nat. Gas‐New)• 300,000 PPH Steam (Nat. Gas‐Existing)• 26,000 Tons Chilled Water (Steam)• 9.7 MW Back Pressure T/G



Steam Summary

• 2,100,000 PPH Total (2014)

• 1,800,000 PPH Firm

• 1,316,000 PPH Peak

Chilled Water Summary

• 76,000 Tons Total (2015)

• 67,500 Tons Firm

• 64,000+ Tons Peak

Electrical Summary

• 71 MW Peak

Campus Utility Summary


Radio Hall 1887 – 1908

Ag Bulletin 1889 – 1908

Service Building Annex 1908 – 1958

Charter Street Heating Plant 1958 – Present

Walnut Street Heating Plant 1975 – Present

West Campus Cogeneration Plant 2005 – Present




Main Campus

Radio Hall 1887 – 1908


Agriculture Campus

Ag Bulletin 1889 – 1908




Campus Aerial, ca. 1900


Central Heating Plant

Service BuildingAnnex1908 – 1958




Present Configuration

Walnut Street Heating Plant (WSHP)

West Campus Cogeneration Facility (WCCF)

Charter Street Heating Plant (CSHP)


Walnut Street Heating Plant (WSHP)

West Campus Cogeneration Facility (WCCF)

Charter Street Heating Plant (CSHP)

Present Configuration

3.5 + Miles Walkable Tunnel190 + Steam Pits? Miles of Inaccessible Box Conduits



CSHP Plant History

Constructed in 1958

Three 100,000 PPH Spreader Stoker Boilers Manufactured in 1953, Purchased Second Hand From Hudson Motors

One 200,000 PPH Spreader Stoker Boiler Installed in 1964

One 300,000 PPH Gas/Oil Boiler Installed in 1970

Baghouse Constructed in 1985

Chilled Water Plant Building Additions in 1965 & 1973

9.7 MW Back Pressure Steam T/G Installed in 1995

CSHP Legal History

Sierra Club Files Open Records Request in 2006

Sierra Club Indicates Filing of Lawsuit in December 2006

Sierra Club Files Lawsuit in May 2007

On November 7, 2007, the US District Court for Western District of Wisconsin Issued a Decision Finding That Three of Five Projects Between 1996 and 2004 Violated the Clean Air Act’s NSR Provisions



CSHP Legal History

US District Court for Western District of Wisconsin Findings

Project

Routine Maintenance, Repair or Replacement (RMRR)FindingsNature and Extent

Purpose Frequency CostDescriptionDuration (Days) RMRR

Like-Kind Replacement

Applicable Test

CAA Modification

1Boiler 4 Rear Wall

Replacement (73 WaterwallTubes and Casing)

45Maintain Pressure Integrity

One or Two Times in

Boiler Life, Not Routine

$97,300 Yes N/A N/A No

2Boiler 4 Side Wall

Replacement (67 WaterwallTubes and Casing)

<45Increase

Availability and Reliability

Two or Three Times in

Boiler Life, Not Routine

$77,000 No YesActual to Projected

ActualNo

3 Boiler 1, 2 and 3 Economizer Replacement 183

Increase Availability and

Reliability

Two Times in Boiler Life, Not Routine

$788,899 No No Actual to Potential Yes (1)

4 Boiler 1 Stoker Feeder Replacement 81

Increase Boiler Efficiency,

Availability and Reliability


$90,700 No No Actual to Potential Yes (1)

5

Boiler 4 Stoker Feeder Replacement and Boiler 1, 2

and 3 Generating Bank/ Superheater Replacement

274 (9 mo.)

Increase Boiler Efficiency,

Productivity, Availability and

Reliability


$1,712,348 No No Actual to Potential Yes (1)

(1) Modified without preconstruction PSD permit so CSHP is subject to best available control technology (BACT) and must apply forrevised operating permit.

CSHP Legal History

Sierra Club Files Open Records Request in 2006

Sierra Club Indicates Filing of Lawsuit in December 2006

Sierra Club Files Lawsuit in May 2007

On November 7, 2007, the US District Court for Western District of Wisconsin Issued a Decision Finding That Three of Five Projects Between 1996 and 2004 Violated the Clean Air Act’s NSR Provisions

On November 21, 2007, Sierra Club and State of Wisconsin Announce a Consent Decree to Transition Charter Street and 12 Other Coal‐Burning Facilities

• 15% Coal Reduction at CSHP Beginning 1/1/08

• Feasibility Study for CSHP and CHPP By 7/2008

• Lookback Study for 12 Other Coal‐Burning Facilities By 12/2008 (Eight Univ. of Wisconsin Institutions)



CSHP Comprehensive Heating Plant Study, July 2008 Four Options Analyzed

• Option 1 – BACT on Existing Coal Boilers, New Gas Boiler

• Option 2 – Integrated Gasification Combined Cycle Including Six Gasifiers and Two 350,000 PPH Syngas Fired Boilers

• Option 3 – Two 350,000 PPH Gas/Oil Boilers

• Option 4 – Two 350,000 PPH Hybrid Biomass CFB Boilers

Notes: - Options 2, 3 and 4 Retire Existing Coal Boilers and Include Back Pressure Steam Turbine Cogeneration

- Options 2 and 4 Capable of Burning Biomass and Fossil Fuels




Original Project Scope

• Two 225,000 PPH Packaged Gas/Oil Boilers

• One 350,000 PPH Biomass Boiler w/AQCS and Solid Fuel Handling

• Offsite Rail and Bike Path

• 20 MW Back Pressure Steam Turbine Cogeneration

• Balance of Plant Upgrades

• Decommissioning of All Four Coal Fired Boilers

• $250.6 Million Project Cost



2010 Conceptual


Concept Diagrams


Concept Diagrams




Project Budget (Enumerated at $250,600,000)Phase A – Packaged Boilers

Phase B – Biomass Boiler, AQCS and Solid Fuel Handling

Phase C – Offsite Rail and Bike Path

Phase D – Steam Turbine Generator

Phase E – Balance of Plant

$ 20,000,000

111,600,000

4,400,000

12,200,000

36,000,000

Overhead and Contractor Fee

Owners Costs

16,000,000

50,400,000

200,200,000

Total Project Cost 250,600,000



Original Project Scope

• Two 225,000 PPH Packaged Gas/Oil Boilers






• $250.6 Million Project Cost

Revised Project Scope

• Four Two 225,000 PPH Packaged Gas/Oil Boilers






• $188.3250.6 Million Project Cost


Revised Project Scope

• Four Two 225,000 PPH Packaged Gas/Oil Boilers






• $188.3250.6 Million Project Cost




November 2010


February 2011




May 2011


July 2011




July 2011


October 2011




January 2012


February 2012




March 2012


April 2012




May 2012


May 2012




May 2012


August 2012




September 2012

Plant Dispatching

MG&E Sp‐3



Plant Dispatching

MG&E Sp‐3

• Generation Credit

• $0.12329 per kW per Day

• Special Terms & Provisions

• UW Owns a Share of WCCF (100% Chilled Water, 25% Thermal)

• WCCF Generators are Operating, Chillers Receive Station Service, No Demand

• WCCF Off (Available), On‐Peak, 8,500 Btu/kWh Heat Rate (Daily or FOM Gas)

• WCCF Off (Available), Off‐Peak, Sp‐3, No Demand

• WCCF Off (Not Available), Real‐Time LMP Plus 10%

Plant Dispatching

MG&E LS‐1



Plant Dispatching

MG&E LS‐1 + IGD‐1 Distribution ($0.0343/Therm)

Plant Dispatching

Cooling Season Dispatch Order (Current)

• WCCF (1) 20,000 Tons (Electric) No Demand

• CSHP 26,000 Tons (Steam) + Cogeneration

• WSHP 9,000 Tons (Steam)

• WSHP 11,000 Tons (Electric) Plus Demand

Notes: (1) In 2015, an additional 10,000 tons will be available at WCCF. This capacity is subject to demand charges.



Plant Dispatching

Heating Season Dispatch Order (Current)

• Firm Capacity (Unaffected by Electric “Blips”)

• CSHP (1) 300,000 PPH + Cogeneration

• WCCF (2) 200,000 PPH (15% Dispatch Benefit)

• WCCF (3) 200,000 PPH (15% Dispatch Benefit)

• Non‐Firm Capacity (Electric “Blips” Can Cause Boiler Trips)

• WSHP/CSHP 1,050,000 PPH

Notes: (1) In 2014, an additional 450,000 PPH of firm capacity will be available at CSHP (2) UW is responsible for uneconomic dispatch costs when WCCF is not selected by MISO (<25 MW)(3) UW takes additional steam when WCCF is selected by MISO

Plant Dispatching

MG&E Sp‐3

Current

MG&E Proposed2013 Rate Case



Plant Dispatching

Cooling Season Dispatch Order (Future?)

• WCCF (1) 20,000 Tons (Electric) No Demand

• WCCF 10,000 Tons (Electric) Plus Demand

• WSHP 11,000 Tons (Electric) Plus Demand

• CSHP 26,000 Tons (Steam) + Cogeneration ?

• WSHP 9,000 Tons (Steam)

Heating Season Dispatch Order (Future?)

• Same as Previous

Questions

uw madison september 13, 2012 -...

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