Air Force Center for Engineering and the Environment Massachusetts Military Reservation ·...

Air Force Center for

Engineering and the

Environment

Massachusetts Military

Reservation

28 Mar 2012

Rose H. Forbes, P.E.

AFCEE/MMR

Federal Government and Military

Projects: Success Story, Current

Trends & Best Practices

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Primarily PCE, TCE, and EDB Concentrations generally < 1 mg/L

Plumes are typically deep (>100 ft)

and thick (>100 ft)

9 treatment plants treating 12 MGD (down from 17.8 MGD)

> 27 miles of pipeline

> 100 EWs and RWs

> 3,000 MWs

Sustainability Evaluation

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Wind I • Fuhrlaender 1.5 MW, 80 m hub, 77 m rotor

• Five year project; date of operation 2 Dec 09

• Expected to produce ~ 3,810 MWh annually based on 29% capacity factor (P50); ~ 3,377 MWh annually based on 25.7% (P90)

• Expected to generate 25-30% of AFCEE’s total electrical requirement (>$2M in 2009; $1.7 M in 2011)

•Actual production: see chart on next slide; capacity factor @17% for Year 1, 24% Year 2, 28% Year 3 (to date)

• Comparison of energy production to energy use: see chart on next slide

• Expected to reduce ~25-30% air emissions

• Payback originally anticipated in 6-8 years (RECs/O&M); latest ROI/SROI showing ~10 years

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• will insert when the chart is ready

Insert Use vs Production Chart

25 Jan – 23 Feb 2011

$689,432: 02 Dec 2009-26 Dec 2011 (+ $60,000 availability guarantee for first year and meter problem)

Wind II

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Wind II • Two GE 1.5 MW, 80 m hub, 77 m rotor • Two year project; date of operation 8 Nov 11

• Expected to produce ~ 7,620 MWh annually based on 29% capacity factor (P50)

• Expected to generate 50-60% of AFCEE’s total electrical requirement (>$2M in 2009; $1.7 M in 2011)

• Actual production: 3250.25 MWh to date; capacity factor @35.5%

• Expected to reduce ~25-30% air emissions

• ROI/SROI showing ~10 years

Details Wind I Wind II

Machines One Fuhrlaender 1.5 MW Two GE 1.5 MW

Hub height/rotor diameter 80 m/77 m 80 m/77 m

Total height ~390 ft ~390 ft

Startup Date (witness test) 2 Dec 2009 8 Nov 2011

Project Timeframe ~5 years ~2 years

Distance from homes 1140 ft (on base residents) 3000 ft (off base residents)

Foundation Spread form – 57’ diameter, 600 yds 5000 psi

concrete

Spread form – 47’ diameter, 470 yds 5000 psi concrete

Blades ND: 122 ft, 13,600 TX: 121.4 ft, 13,900 lbs

Tower Sections MN: 4; 41’-79’; 65,000-106,000 lbs IA: 3; 72’-97’ long; 62,700-114,000 lbs

Machine Head GE: 12.8’ high, 26.6’ long, 143,200 lbs FL: 12.5’ high, 29’ long, 126,000 lbs

Crane Manitowoc 16000; 440 ton; 315’ mast Manitowoc 16000; 440 ton; 315’ mast

Funding Type Environmental Restoration Account Environmental Restoration Account

Constructability Assessment $400,000 $462,284

Construction $4.87M (plus two years O&M) $9.43 (plus substation and one year O&M)

Utility Interconnection $53,858 (to existing 23 kV distribution) $272,000 (to new 23 kV distribution line through new

substation and then to existing 115 kV transmission line)

Title II Oversight $150,000 $341,000 (and environmental surveys)

Energy Production (startup to date) 6145 MWhr (02 Dec 09 - 14 Mar 12) 3250 MWhrs (8 Nov 11 - 14 Mar 12)

Capacity Factor Ranged from 17% in first year to 24% in second

year; 28.5% third year to date

35.5% to date

ROI 9-10 years 9-10 years

Notable Issues/Lessons Learned

• Communicate early and often with stakeholders

• Understand net-metering, RECs, and state rules

• Utility Interconnection – build in time and plan for costs

• Logistics - room to haul and build (bridges, road width, corners, permits, bad drivers, Military Cargo Preference Act of 1904, etc)

• Explore additional grants – can AF/DoD accept them?

• Inspect the manufacturing facilities if possible

• Make sure the turbine components suppliers and transportation companies are insured.

• Evaluate modes of transportation (roadway, rail, barge)

• Contracting: Firm Fixed Price or Cost (Best Value or Lowest Price)

• Do spare parts come with the wind turbine purchase? • Just because spare parts are new doesn’t necessarily mean

they will work • Plan for technical and safety training – involve local

emergency response personnel • An FAA ruling of presumed hazard is not the end of a project,

it’s the beginning of negotiations • Ensure manufacturers are reputable and there are working

wind turbine models in the US for several years • Select contractors who have experience with wind turbine

planning and construction projects • Are anchor bolts sized correctly? Metric vs english conversions

can cause problems • Provide site signage/directions to transportation companies

and police details

Notable Issues/Lessons Learned

Notable Issues/Lessons Learned • Construct foundation in cool weather and allow time to achieve

strength • Long lead time on turbines - explore interest from manufacturers

(important on Wind I, not so much on Wind II) • Plan on a schedule and hold contractors to it – include liquidated

damages in contracts • Use existing wind resource data and other studies if available and

applicable • Evaluate warranties and O&M/service contracts in advance; build

in availability guarantee • Consult experts (i.e. DOE, AFCESA) on funding mechanisms

(DERA, ECIP, EULs, ESPCs, tax credits) • Don’t plan a ribbon cutting ceremony until the turbine is up and

operational • Long Haul Project – need a dedicated champion • What about O&M????

Examples of Other Projects - MMR

• PAVE PAWS wind turbines – ECIP funds, own & operate

• 102 IW (ANG – Otis) – solar PV on landfill (DLA – developer based PPA)

• The VA cemetery installed a smaller wind turbine (50 kW) on their property

• USCG uses a geothermal heating/cooling system at one of its hangars and is incorporating geothermal in a new hangar construction project

Examples of Other Projects

• USACE-Kansas City wind turbine project

• FE Warren – Cheyenne WY wind turbines

• See AFCESA website for additional projects at AF/ANG bases

• Town of Plymouth wind turbines; land lease developer based PPA

• Town of Plymouth solar PV on landfill – land lease, developer based PPA

Issues for Wind Developers • Land lease on federal property can be

complicated

• Price of solar << than wind turbine in a power purchase agreement (especially in MA)

• Utility interconnection

• AFCESA, AFCEE, USACE, DLA, GSA – get to know your toolbox of selected contractors

• Central Contractor Registration (register)

• Federal Business Opportunities

Issues for Wind Developers • Engineering Technical Letter (ETL) 11-1 (dated

30 Mar 2011): Civil Engineer Industrial Control System Information Assurance Compliance

• Contact agencies and toolbox contractors and provide company information

• DoD getting familiar with wind projects but not quite there yet

Agencies/Contacts

• Air Force Civil Engineering Support Agency (AFCESA) -AFCESAReachBackCenter@tyndall.af.mil

• Air Force Center for Engineering and the Environment (AFCEE)

http://www.afcee.lackland.af.mil/contracting/contracts.asp

• Air Force Real Property Agency (AFRPA)

http://www.safie.hq.af.mil/afrpa/index.asp

• Defense Logistics Agency

http://www.dla.mil/Pages/default.aspx

Agencies/Contacts

• US Army Corps of Engineers

• Federal Business Opportunities: https://www.fbo.gov/

• Central Contractor Registration: https://www.bpn.gov/ccr/default.aspx

QUESTIONS/COMMENTS?

rose.forbes@us.af.mil

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Energy Optimization

• Wellfield optimization • Use of passive diffusion bag sampling • Use of direct push rig vs larger sonic/auger rig • On site O&M/well maintenance • Installation of VFDs and premium efficiency

motors • Elimination of booster pumps and pump

motor downsizing • Replaced sodium vapor overhead lighting • Use of bio-diesel, soy based hydraulic fluid • Reduction in propane use • Installation of low-wattage heaters • Misc energy (motion sensors, lighting

replacement, programmable thermostats, LED exit lighting, new windows, etc.)

• Signed up with the load reduction program (demand response program)

• Evaluated utility rate structures

Distance from turbine to base

housing ~ 1140 ft

Activities • Completed Constructability Assessment [Basis of Design, Economic

Analyses, Environmental Assessment (EA)]

• EA Public Comment Period; FONSI signed in Nov 2010

• Submitted Interconnection application to NSTAR

• FAA studies approved

• PAVE PAWS evaluation approved

• Coordination with other agencies and community completed – EMC/SAC/CAC, USFWS , MA NHESP, MHC/BHC, THPO, MA FWS, MMRCT/SMB, news

releases

• Awarded construction project in Sep 2010 to ECC ($9.4M)

• Initial clearing of two turbine sites in Oct/Nov 2010, included turtle surveys and baseline invasive species survey

• Grubbing, cut/fill and substation clearing in March/April 2011 , included Eastern Box turtle surveys

• Pre- and post-construction bird/bat surveys started/continuing

Foundations

~470 yds 5000 psi concrete

47’ diameter

Spread form design

Completed in May 2011

Blades - Texas

• Insert photo Length = 121.4 ft

Weight = 13,900 lbs

Fiberglass construction

Arrived 7 Jun 2011

Tower Sections - Iowa

Mid: 80,700 lbs; 85 ft long;

14 ft diameter at base

Top: 62,700 lbs; 97 ft long; 11 ft diameter at base

Base: 111,400 lbs; 72 ft long; 15 ft diameter at base Steel construction

Arrived June/July 2011

Tower Sections (cont)

Mid section hit an overpass in

Indiana on 22 Jun 2011

Driver varied from permitted route

Damage was cosmetic;

tests/repairs conducted on site

Machine Head - Florida

126,000 lbs

12.5 ft high

29 ft long

Under Construction

• Both wind turbines installed late June through mid July 2011

View from Scenic Highway (across the canal)

Both turbines produced a

combined total of 2173

MWhr from 04 Nov 2011 –

31 Jan 2012

View from Sagamore Bridge

Ribbon Cutting