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

7

• 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