integrated, automated distributed generation (dg ... 2010 peer review... · • develop and...

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


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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


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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


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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


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Where in the World Is Promontory, UT?

Reno 518 m.


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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


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ATK Promontory Photos


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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


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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


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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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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


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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


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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


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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


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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


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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


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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


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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)


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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


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Promontory Demand Profile

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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


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Demand Reduction – Data Analysis

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500

1000

1500

2000

2500

3000

8:15

8:30

8:45

9:00

9:15

9:30

9:45

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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


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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


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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

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11:0

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11:1

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kW

Limit

Peak DemandAugust 13

15% DemandReduction Period

Emphasized

9:30 18:45

Demand Response Period 9 hours 15 min


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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

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11:1

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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


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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)


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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


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Contact Information

Roger WeirATK Aerospace Systems

PO Box 98, M/S G2UTMagna, UT 84044-0098

[email protected]

Smart Grid Peer Review, Denver, CO

November 2-4, 2010

mailto:[email protected]�

integrated, automated distributed generation (dg ... 2010 peer review... · • develop and...

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