it’s all about energy · 2017. 10. 17. · it’s all about energy mdc’s on-site power generaon...

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

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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

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MapofSewerServiceArea

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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

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HarBordWPCF

HarBordLiquidTreatmentProcess

Primary

SecondaryBNR

SeasonalUVDisinfec<on

ToConnec<cutRiver

Preliminary

DynamicSeparators

WetWeatherPumpSta<on

StorageLagoon

PrimaryEffluentPumpSta<on

HighCTRiverEleva<on

PumpSta<on

LagoonOverflowChlorina<on

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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

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DistrictWideElectricityUsage

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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

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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

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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

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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

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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

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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!

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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

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SteamBlow–CleanOutPriortoStart-Up

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SteamBlow–CleanOutPriortoStart-Up

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WHRBuilding

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Boilers

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Turbine&Generator

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WaterTreatment

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BoilerWaterSystem

29Deaerator

CondensateTankSurfaceCondenser

ElectricalRoom

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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

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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)

Ques<ons?ContactTomTyler

dyler@themdc.com

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