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A premier aerospace and defense company
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Integrated, Automated Distributed Generation (DG) Technologies Demonstration
Presented by:Roger WeirEnergy ManagerATK Aerospace Systems
Smart Grid Peer Review, Denver, CONovember 2-4, 2010
A premier aerospace and defense company
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Background / Overview
About ATK and the facility:• What Is ATK?• Where is the Promontory plant?• Promontory facts• Pictures
About the DG project:• DG original project concepts• Phase I implementation• Phase I lessons learned• Phase I extension project• Plant demand analysis• DG project summary
• ATK conducted a comprehensive plant-wide energy assessment (PWA) in FY07 and FY08.
• In 2008, initiated agreement with DOE/NETL for Phase I of distributed generation (DG) development project
• 2009 into 2010 – Phase I project
• Significant financial and technology adjustments
• 2010 agreement and funding for a Phase I extension
A premier aerospace and defense company
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What Is ATK?
• A premier aerospace and defense company with approximately 18,000 employees and operations in 24 States and Puerto Rico
• Incorporated in 1990 when Honeywell Inc. spun off its defense businesses to its stockholders
• Entered the aerospace market in 1995 with the acquisition of Hercules Aerospace and, in April 2001, added Thiokol Propulsion
• Leading supplier of aerospace and defense products to the U.S. government, allied nations, and prime contractors
• Major supplier of ammunition and related accessories to law enforcement agencies and commercial customers
Alliant Techsystems Inc. (ATK)
Promontory Plant
A premier aerospace and defense company
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ATK Current Business Overview
ATK is organized into four operating groupsAerospace SystemsPresident: Blake Larson
• Solid propulsion systems
• Advanced composites
• Satellites, subsystems, and components
• Advanced antennae and radomes
• Energetic materials
• Military flares and decoys
• Small-caliber ammunition
• Medium-caliber ammunition
• Medium-caliber gun systems
• Precision munitions
• Propellants for ammunition and tactical rockets
• Large-caliber ammunition
Armament SystemsPresident: Karen Davies
• Missile systems
• Solid propulsion and control systems
• Solid rocket motors and warheads
• STAR motors
• Aircraft survivability
• Advanced structures and components
Missile ProductsPresident: Mike Kahn
• Small-caliber ammunition
• Gun care and shooting accessories
• Sport shooting accessories and reloading supplies
• Law enforcement accessories and equipment
Security & SportingPresident: Ron Johnson
A premier aerospace and defense company
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Where in the World Is Promontory, UT?
Reno 518 m.
A premier aerospace and defense company
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ATK Promontory “City” Facts
• 19,900-acre plant site
• Over 540 buildings
• 75 miles of roads
• 70 miles each of steam, condensate, and compressed air lines
• 60 miles of electrical power lines
• 75 miles of water lines
• Two waste water treatment plants
• 28 boiler houses
• Three main electrical substations
• Annual energy bill over $15,000,000
A premier aerospace and defense company
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ATK Promontory Photos
A premier aerospace and defense company
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Demonstrate that distributed/renewable resources can provide meaningful benefits to customers/users and utility/interconnected grid
ATK Promontory Project
Overall Project Purpose and Objectives• Develop and demonstrate a diverse system of renewable DG technologies that are
integrated into an intelligent system-wide automation system with two-way communications to the utility and that will produce a verifiable, on-demand reduction of at least 15% of substation load with no disruption of facility operations.
Major Milestones• Design and test renewable DG systems controls
• Design and test the utility/customer gateway
• Engineer and install 2.6 MW of diverse, renewable, distributed generation
• Demonstrate system operations
• Measure and validate savings and systems benefits
A premier aerospace and defense company
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ATK Project Original Structure
Total Project Cost $3,769,052 Phase I(FY09)
Phase II(FY 10 – FY13)
Total Budget $878,673 $2,890,379 DOE Share 80/50% $702,938 $1,445,190
P&E Cost Share 5/10% $43,934 $289,038 ATK Share 15/40% $131,801 $1,156,152
RMP Incentive (reimbursement) $0 $700,000 Annual energy savings $800K
Project Partners:• ATK Aerospace Systems – project management/host• P&E Automation (San Diego, CA) – technology/experience• Rocky Mountain Power (Div. of PacifiCorp) – interface/incentives
Structure: Phase I – development, Phase II – demonstration
A premier aerospace and defense company
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Project Management – milestone based tracking
Recent DOE plant-wide assessment• Tracked budget and task milestones against baselines • Same management team in place
Tracking metrics alert to deviations BEFORE they impact project success• Budget plan-to-actual• Schedule plan-to-actual• Fine-grained milestone plans — projects can have hundreds of trackable milestones
DOE PWA Monthly Status
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10
20
30
40
50
60
70
80
90
100
M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15
Project Month
% C
ompl
ete
Budget Baseline
Budget Complete
Milestone Baseline
Milestone Complete
A premier aerospace and defense company
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Project Overview
Demand Reduction / Peak Shaving:
Renewable Distributed Generation• Mix of renewable technologies
• Integrated monitoring and control
– Includes automated measurement and verification
– Can be integrated with future plant-wide system control and data acquisition (SCADA)
Customer/Utility communications: Utility Gateway Application• Provides utility real-time visibility into customer-owned renewable DG resources• Two-way Customer <> Utility web interface
– Real-time behind-the-meter customer generation data– Real-time utility distribution, capacity and quality data– Extensible to include real-time pricing– Day ahead dispatch notification
A premier aerospace and defense company
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DG Implementation Summary
Phase I Development (Year 1 – FY2009)
• Design and testing of reliable and effective DG controls
• Design and preliminary testing of utility gateway hardware and software
• Collect/compile historical baseline data
• Provide full design, engineering, specifications of DG
• Design and installation of sufficient generation equipment to validate
Phase II feasibility
– Two wind turbines (2 kW each)
– One micro-hydro turbine (10 kW)
– One compressed air generation/storage device (20 kW)
Decision point: Successful completion of Phase I, mutual agreement to proceed with Phase II
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Project Equipment – Wind
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Project Equipment – Hydro
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Project Equipment – Compressed Air
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Project Equipment – Controls
Single Board PC
120v Brkr Power
Supply
To Generator
120V
Ethernet
Controlrelays
PC• Std IT operating systems• Ethernet connectivity• Two-way communications
to generator controller• Digital and analog I/O• Std IT database storage• Low cost
A premier aerospace and defense company
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Project Presentations
• DOE Peer Review – Red Bank, NJ – Oct 2008
• Energy Congress – Atlanta – Apr 2009 – Voldness
• Energy Solutions Center – Salt Lake City – Jun 2009
• Utah Public Service Commission – Jul 2009
• Questar Annual Customer Meeting – Sep 2009
• FMA Congress – Chicago – Sep 2009 – Gosen
• International MicroGrid Symposium – San Diego – Sep 2009
• Utah Energy Users – Salt Lake City – Oct 2009
• Utah Energy Forum – Utah State Capital – March 2009
• Utah Public Service Commission – Promontory site visit – May 2010
• MicroGrid Update – Teleconference – May 2010
A premier aerospace and defense company
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Lesson Learned
Interconnection agreement
• First meeting – $100K cost two years
• Application process and fast track process
• Approval – utility is in control and can be a huge impediment
Utility interface and cooperation
• No tariffs, no way to ensure recovery of costs
• Look other way, allow us to hook up with appropriate technical personnel
Viability of large-scale hydro storage
• No viable “run of pipe” installation locations (large pipe, small flows)
• Must have upper and lower storage capacity for effective demand capacity
A premier aerospace and defense company
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Lesson Learned
Viability of compressed air storage
• Better to eliminate sources of waste compressed air versus generating, knowing when excess can be stored, collecting waste, amplifying, and storing at high pressure
• Generating unit had significant “parasitic” loads; not yet found way to de-energize and then operate properly when needed
Viability of compressor waste heat for electric generation
• Waste heat from compressors is too low temperature to efficiently use in an ORC unit
Use of standard IT equipment and operating systems for monitoring/control/data collection
• Successfully used standard single board, solid-state-storage PCs running Lynexoperating systems; to talk to the generation equipment and then process and send data to a central database for storage
• Database source of all data for control and measurement and reporting
• Used existing plant Ethernet for communication to PCs and database
A premier aerospace and defense company
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Lesson Learned
15% demand control with planned mix/type of resources
• Study of plant kW curves
– 76% avg load factor
– 15% demand reduction required 10 – 12 hours per day of peak resource operation
- Compressed air resources limited to less than one hour per day operation
- Hydro resource maximum of three hours per day
– Needed to re-plan an effective 15% demand reduction generation equipment mix
Utility scale battery storage options
• Investigated battery storage option
• 500 kW capacity for five hours per day
• Use of wind and boiler waste heat recovery for re-charging battery
• Good match for a 3 – 4% demand reduction
A premier aerospace and defense company
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Phase I Extension approach
• Battery can provide 500 kW for up to 5 hours per day
– Battery system are fully self contained requiring minimal installation and integration costs
• Steam boilers stack waste heat is a viable source for current Organic Rankine Cycle technology (temperatures above 300 F)
– Will provide waste heat operating experience that should prove useful for potential future geothermal generation (Phase II?)
• Wind generation can be scaled to provide energy to recharge battery for a true renewable resource
• Waste heat capacity will provide energy for battery recharge.
• Battery charge/discharge cycles will be tested to optimize cycle versus simple full daily charge and discharge.
• Utility off-peak energy price differential to on-peak may also prove to be a cost effective source of battery recharge ($.022518 versus $035858/kWh, 59 percent higher not including peak demand or facility charges)
A premier aerospace and defense company
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DG Implementation – Phase I Extension
Two-year project – Oct 2010 to Sep 2012
Project cost $1.8M; DOE $1,445K, ATK $361K
• Project scope– One wind generator – 100 kW– Two waste heat recovery generators – boiler stack – 50 kW ea – 100 kW– One battery storage unit – 500 kW
• Data collection– Utility gateway two-way communications– Automated measurement & verification– Automated optimization of DG resource usage (3.4% demand reduction)
- or RMP system peak reduction– Validate operational savings – $150K/year
A premier aerospace and defense company
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Promontory Demand Profile
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
KW
August Demand
Peak day Aug 13
15% Demand limit
3.4% Demand limit
A premier aerospace and defense company
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Demand Reduction – Data Analysis
0
500
1000
1500
2000
2500
3000
8:15
8:30
8:45
9:00
9:15
9:30
9:45
10:0
0
10:1
5
10:3
0
10:4
5
11:0
0
11:1
5
11:3
0
11:4
5
12:0
0
12:1
5
12:3
0
12:4
5
13:0
0
13:1
5
13:3
0
13:4
5
14:0
0
14:1
5
14:3
0
14:4
5
15:0
0
15:1
5
15:3
0
15:4
5
16:0
0
16:1
5
16:3
0
16:4
5
17:0
0
17:1
5
17:3
0
17:4
5
18:0
0
18:1
5
18:3
0
18:4
5
19:0
0
19:1
5
19:3
0
19:4
5
20:0
0
Distr
ibute
d Gen
erat
ion kW
Promontory15% Demand Reduction Curves
August 2009Peak 17,926 - 85% Peak Limit 15,237
8/3/2009
8/4/2009
8/5/2009
8/6/2009
8/10/2009
8/11/2009
8/12/2009
8/13/2009
8/14/2009
8/17/2009
8/18/2009
8/19/2009
8/20/2009
8/21/2009
8/24/2009
8/25/2009
8/26/2009
8/27/2009
8/28/2009
8/31/2009
A premier aerospace and defense company
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Demand Reduction – Data Analysis
0
100
200
300
400
500
600
700
10:00 10:15 10:30 10:45 11:00 11:15 11:30 11:45 12:00 12:15 12:30 12:45 13:00 13:15 13:30 13:45 14:00 14:15 14:30 14:45 15:00 15:15 15:30 15:45 16:00 16:15 16:30 16:45
Requ
ired
Dis
trib
uted
Gen
erat
ion
kW
Promontory4% Demand Reduction Curves
August 2009Peak 17,926 - 96% Peak Limit 17,276
8/3/2009
8/4/2009
8/5/2009
8/6/2009
8/12/2009
8/13/2009
8/20/2009
A premier aerospace and defense company
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Peak Demand Reduction – 15%
14,000.0
14,500.0
15,000.0
15,500.0
16,000.0
16,500.0
17,000.0
17,500.0
18,000.09:
00
9:15
9:30
9:45
10:0
0
10:1
5
10:3
0
10:4
5
11:0
0
11:1
5
11:3
0
11:4
5
12:0
0
12:1
5
12:3
0
12:4
5
13:0
0
13:1
5
13:3
0
13:4
5
14:0
0
14:1
5
14:3
0
14:4
5
15:0
0
15:1
5
15:3
0
15:4
5
16:0
0
16:1
5
16:3
0
16:4
5
17:0
0
17:1
5
17:3
0
17:4
5
18:0
0
18:1
5
18:3
0
18:4
5
kW
Limit
Peak DemandAugust 13
15% DemandReduction Period
Emphasized
9:30 18:45
Demand Response Period 9 hours 15 min
A premier aerospace and defense company
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Peak Demand Reduction – 3.4%
14,000.0
14,500.0
15,000.0
15,500.0
16,000.0
16,500.0
17,000.0
17,500.0
18,000.09:
00
9:15
9:30
9:45
10:0
0
10:1
5
10:3
0
10:4
5
11:0
0
11:1
5
11:3
0
11:4
5
12:0
0
12:1
5
12:3
0
12:4
5
13:0
0
13:1
5
13:3
0
13:4
5
14:0
0
14:1
5
14:3
0
14:4
5
15:0
0
15:1
5
15:3
0
15:4
5
16:0
0
16:1
5
16:3
0
16:4
5
17:0
0
17:1
5
17:3
0
17:4
5
18:0
0
18:1
5
18:3
0
18:4
5
Peak DemandAugust 13
15% vs. 3.4% DemandReduction Periods
Emphasized
9:30 18:45
Demand Response Period 9 hours 15 min
13:30 to 16:00 hours
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Demand Reduction – Fixed Resource
0.0
2,000.0
4,000.0
6,000.0
8,000.0
10,000.0
12,000.0
14,000.0
16,000.0
18,000.0
20,000.0
kW
Limit
W Ctrl
Demand Reduction Curvewith 15% reduction fromfixed resource
A premier aerospace and defense company
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Demand Resource – Load Following
0.0
2,000.0
4,000.0
6,000.0
8,000.0
10,000.0
12,000.0
14,000.0
16,000.0
18,000.0
20,000.0
kW
Limit
W Ctrl
Demand Reduction Curvewith 15% reduction fromoptimally dispatchedresource(s)
A premier aerospace and defense company
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Demand Resource – Utility Dispatch
0.0
2,000.0
4,000.0
6,000.0
8,000.0
10,000.0
12,000.0
14,000.0
16,000.0
18,000.0
20,000.0
kW
Limit
W Ctrl
System/grid dispatchFixed 4 hour block
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Summary/Benefits
Project will provide NETL with extensible technologies
• Gateway application provides utility with real-time visibility to customer renewable and storage DG capacity
• Controls based on open, IT standards for portability to other utilities and customers
• Use of utility grade battery system for renewable energy storage and demand control
• Use of boiler waste heat for electric generation using ORC
Unique monitoring/control application optimizes mixed DG for demand control
• Application to determine real-time optimal usage of DG resource based on– resource availability (wind)– peak load– available stored energy– on and off peak energy cost differentials– utility dispatch
A premier aerospace and defense company
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Contact Information
Roger WeirATK Aerospace Systems
PO Box 98, M/S G2UTMagna, UT 84044-0098
801-251-2063roger.weir@atk.com
Smart Grid Peer Review, Denver, CO
November 2-4, 2010
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