POWER GENySYS Burlington, Ontario. PORT COLBORNE GENERAL HOSPITAL Above: Entrance of,. 2 nd Hospital Cogeneration System in Ontario (1993) In 1993 Marsh Energy Inc. was awarded a turnkey contract by the Port Colborne to design, build, operate and maintain the 2 nd hospital cogeneration system in Ontario utilizing a natural gas reciprocating engine-generator with steam heat recovery. The system prime-mover is a Caterpillar Model 3306 natural gas fuelled reciprocating engine-generator set, producing 150 kw e of load displacement electricity (no export), approximately 240 lbs/hr of steam at 125 psig from the exhaust heat recovery steam generator, and about 165 kw th of hot water from the oil cooler and jacket water cooling circuits. Heat recovery was not incorporated for the aftercooler circuit. Under normal operation the plant is unmanned. The engine-generator set was located in an acoustically separated room, adjacent the boiler plant in the basement level, and next to the exhaust heat recovery steam generator (), (photos, right & below-right). To achieve the low NO X emission levels required for the site, the system had to be equipped with a catalytic convertor and special Altronic airfuel ratio controller, which tuned the engine for rich-burn operation. To minimize noise transmission, the combustion and ventilation air inlet opening as well as the ventilation air outlet where fitted with specially designed silencers. Engine exhaust piped to the was exhausted through unused stack for the decommissioned boiler, (photo, below-left). Services: ( Provided by: Vito Mike Casola, P.Eng., Engineering Manager, Marsh Energy Inc. ) Verification of Project Feasibility / Economic Analysis, Detailed Engineering Design and Drafting, Procurement of all Major and Auxiliary Equipment, Preparation of Contract Documents and Contract Administration, Project Management and Construction Supervision, Startup / Commissioning and Operation / Maintenance, Monthly Operational Reports. Above: Silencer CAT 3306 Power & Control Panel Exhaust Bypass & Combustion Air Inlet Motorized Dampers Exhaust Inlet Outlet (125 psig) CAT 3306 genset, genset power & control panel, and Vaporphase. P-1 Exhaust Stack HX-1 CAT 3306 GENSET 150 kwe Cooling Circuit Piping to Roof Mounted Heat Dump Radiator P-6 Air Outlet Damper (silencer inside cogen room) & Combustion Air Inlet Silencer Above: Outdoor view of cogen room, ventilation & combustion air inlet silencer, ventilation outlet damper, and genset cooling circuit piping to remote roof-mounted heat dump radiator. Above: Skid mounted genset (CAT 3306) with heat recovery circuit piping and pumps (P-1 & P-6) to HX-1, and natural gas train. File: PI-93009 - Hospital Cogen 01.DOC 93009 - Page 1 of 15
POWER GENySYS Prime Mover Location and Air System: Burlington, Ontario. An area previously occupied by a decommissioned steam boiler that was removed provided a suitable location to house the cogen system. The space was large enough to accommodate the skid mounted genset, the and a storage tank for preheating laundry domestic water. Elec. Room Air Outlet Opening Air Inlet Opening Natural Gas Line Boiler Room Outline of space allocated for Wall Outline Wall Outline Storage Room (previously a boiler room) sited for the new cogeneration system. Pre-Construction: Outlining limits of new cogen room and major equipment. Exhaust Stack Existing window used as opening for outlet of cogen room ventilation air Exhaust Stack Existing boiler combustion air opening used for inlet of cogen combustion air and cogen room ventilation air. Silencer Elbow Cogen Cooling Circuit Piping to Dump Radiator Engine Exhaust Heat Recovery Steam Generator (). Air Opening, and Cooling Circuit Piping to Dump Radiator. Air Inlet Opening Natural Gas Line Variable Speed Fan Cogen Cooling Circuit Piping to Dump Radiator CAT 3306 GENSET 150 kwe & Combustion Air Inlet Silencer Installation of ventilation / combustion air inlet silencer in existing opening. Variable Speed Fan Vibration Isolation Springs Cogen System Installation: Placement of skid mounted genset and. File: PI-93009 - Hospital Cogen 02.DOC 93009 - Page 2 of 15
POWER GENySYS 2nd Hospital Cogeneration System in Ontario (1993), cont Turbine Flow Meter & Manual Bypass HTCC to Rad HWH-R P-6 Expansion line Natural Gas Train P-1 HTCC HTCC from Rad LTCC from Rad LTCC to Rad Fan Air Outlet Silencer Cooling Circuit Piping to Remote Heat Dump Radiator LTCC to Rad Starting Batteries Burlington, Ontario. At the heart of the cogeneration system is the prime mover; a 150 kwe Caterpillar 3306 natural gas spark-ignited reciprocating engine generator set (genset). The genset was equipped with hot water heat recovery for the Oil & Jacket Water cooling circuit; the High Temperature Cooling Circuit (HTCC). Heat from the HTCC is transferred to the building hot water heating (HWH) system via a plate-frame heat exchanger (HX-1). Pump P-1 pulls hot water from the HWH system supply header and circulates it through HX-1 to capture thermal energy from the genset HTCC and returns it back to the HWH system return header. The recovered heat is utilized by the building heating system, to preheat domestic hot water for general hospital use and to preheat laundry water. Energy utilization is measured by temperature differential and flow, via a turbine flow meter. Left/Right: Skid mounted genset, cooling circuit piping to HX-1/radiator, and gas train. Prime Mover Skid Mounted Engine-Generator Set: HTCC to Rad HX-1 HTCC Power & Control Panel Natural Gas Train LTCC to Rad P-6 Thermostatic 3-way Mixing Valve Cogen Cooling Circuit Piping to Dump Radiator: LTCC, HTCC, & Expansion Lines Catalytic Converter To achieve the low NOx emission levels required for the site, the system had to be equipped with a catalytic convertor and special Altronic air-fuel ratio controller, (photo, left), which tuned the engine for rich-burn operation. Exhaust Air Outlet Silencer Exhaust Power & Control Panel P-1 Left: Skid mounted genset, HX-1, cooling circuit piping to HX-1/radiator, engine exhaust to catalytic converter, Altronic air/fuel ratio controller mounted on the side of the genset control panel. P-1 Cogen Cooling Circuit Piping to Dump Radiator Altronic HX-1 HX-1 Vibration Spring Starting Batteries Starting Batteries File: PI-93009 - Hospital Cogen 03.DOC 93009 - Page 3 of 15
POWER GENySYS Burlington, Ontario. Annunciation Lights Annunciation lights Synchronization Electrical Power & Control Panel & Other Electrical Equipment Electrical equipment located inside the cogen room includes the genset power & control panel (photos right), and genset battery charger (photo bottom-right). The generator power & control panel includes annunciation lights to indicate trouble and warnings. Also included is a generator control switch and control dials / buttons (photo right-middle). The genset control switch allows for manual and auto operation. Other dials and buttons (left to right in photo) include a voltage adjust dial, an alarm accept button, an emergency stop button, a lamp test button, a frequency adjust dial, and a load set dial. An Altronic Air/Fuel Ratio Controller installed on the side of the Control Panel (photos bottom-left & bottom-middle), along with a catalytic convertor limits cogen system NO X emission levels to levels required for the site. Power & Control Panel Generator Breaker Engine control switches and buttons The utility interface/sensing panel is located in the main electrical room and includes double (redundant) utility grade protection relays (below). Power & Control Panel Generator Motorized Breaker: 52-G Air Outlet Silencer Elbow Utility Interface / Sensing Panel Above: Utility Interface/Sensing Panel (Inside Electrical Room) Battery Charger Above: Altronic Air/Fuel Ratio Controller installed on Cogen Power & Control Panel Above: Battery Charger File: PI-93009 - Hospital Cogen 04.DOC 93009 - Page 4 of 15
POWER GENySYS Burlington, Ontario. Variable Speed Fan Auxiliary Equipment Electrical Motor Control Centre (MCC) The cogen system auxiliary equipment is powered through various motor control centers located inside the cogen room. The remote heat dump radiator fans are powered through a disconnect switch and a fan motor starter/controller panel (photo, right & middle-right). The system circulating pumps are powered through a pump motor control center (photo, middle-left & bottom-left). The cogen room variable speed ventilation fan, (photo, right), is powered through a fan motor starter panel and controlled by a separate variable speed controller (photo, middle-left & bottom-right). Power Disconnect Switch Remote Heat Dump Radiator Fan Starter / Controller Panel Auxiliaries: Remote Heat Dump Radiator Fan Starter / Controller. 125 psig steam supply to header Auxiliaries MCC Exhaust to Stack Remote Heat Dump Radiator Fan Starter / Controller Auxiliaries MCC: Pumps MCC, Fan Starter & Variable Speed Controller. Auxiliaries: Remote Heat Dump Radiator Fan Starter / Controller. Motor Control Centre Auxiliaries Auxiliary Equipment Fan Starter Fan Variable Speed Controller HX-1 Circ. Pump P-1 HX-2 Circ. Pump P-2 Feedwater Pump P-4 Laundry Preheat Pump P-3 Hot Water Preheat Pump P-5 Jacket Water Preheat Pump P-6 Auxiliaries MCC: Cogeneration System Pumps MCC. Auxiliaries: Fan Starter & Variable Speed Controller. File: PI-93009 - Hospital Cogen 05.DOC 93009 - Page 5 of 15
POWER GENySYS Burlington, Ontario. Silencer Pneumatic Feedwater Valve Exhaust Bypass Power & Control Panel CAT 3306 Exhaust Inlet Outlet Engine Exhaust Heat Recovery via Heat Recovery Steam Generator: Thermal energy is recovered from the engine exhaust as high pressure steam. The Heat Recovery Steam Generator (), located directly adjacent to the engine-generator set inside the cogen room, generates approximately 240 lbs/hr of steam at 125 psig which is supplied to the main steam header. A backpressure steam valve only releases enough steam to maintain the supply pressure at approximately 125 psig. During periods of low steam usage, below the output of the, steam pressure rises and excess steam blows off through an excess steam blowoff valve, to maintain steam pressure at 135 psig. (125 psig) Feedwater Connection Water Level Controller Boiler Blowdown Line Above: CAT 3306 genset, genset power & control panel, and Vaporphase. 125 psig steam supply to header Pneumatic Feedwater Valve & manual bypass Exhaust Bypass Exhaust to Stack Clorius Boiler Feedwater Magnetic Flow Meter & Manual Bypass Excess Steam Blowoff Valve (Set at 135 psig) Steam Header Backpressure Steam Valve (Set at 125 psig) 125 psig Steam Supply HWH-R Cogen HWH Flow Meter & Manual Bypass HWH-R (Return) HWH-S (Supply) HWH-S Above:, Exhaust Piping, Feedwater Supply and Steam Outlet. Above: Steam Supply, Backpressure Valve, Excess Steam Blowoff Valve. Excess Steam Blowoff Valve (Set at 135 psig) Backpressure Steam Valve (Set at 125 psig) Backpressure Steam Valve (Set at 125 psig) Steam Header HWH-R Steam Supply Steam Supply Above: Steam Supply, Backpressure Valve, Excess Steam Blowoff Valve. Above: Steam Backpressure Valve. File: PI-93009 - Hospital Cogen 06.DOC 93009 - Page 6 of 15
POWER GENySYS Burlington, Ontario. Laundry Water Preheat / Storage and Domestic Hot Water: Exhaust to Stack P-6 Laundry Water Preheat Storage Tank Boiler Feedwater Line P-3 Excess Steam Blowoff P-2 Thermal energy from the cogen system s Jacket Water & Oil Cooler circuits is recovered and transferred to the building s hot water heating (HWH) system, via heat exchanger HX-1. This cogen HWH is then utilized to heat both domestic hot water (DHW) and laundry water. Hot water for the hospital laundry system is preheated by the cogen HWH system, via a double-wall plate-frame heat exchanger (HX-2). Makeup domestic cold water (DCW) enters the tank, where Pump (P-3) circulates water from the storage tank to the heat exchanger (HX-2) and back the tank to preheat the water which supplies the main laundry hot water storage tank. Left: View of Laundry Water Preheat Station inside. Right: Laundry Water Preheat Station, including 100 gallon preheat storage tank, heat exchanger (HX-2) and circulation pumps (P-2 & P-3). Preheated DHW Supply To Laundry Storage Tank New 100 Gallon Laundry Water Preheat Storage Tank DCW Makeup P-3 HX-2 P-2 Cogen HWH Return Cogen HWH Supply Thermostatic 3-way Mixing Valve : Laundry Water Preheat Station. Laundry Water Preheat Tank, HX-2, P-2 & P-3. Existing Primary DHW Storage Tank No.1 converted to preheat DHW P-5 Thermostatic 3-way Mixing Valve DHW Tank No.2 Hospital DHW was previously heated by steam via shell & tube heat exchangers (HX) in primary and secondary storage tanks. The primary DHW storage tank was converted to preheat domestic water. The heat exchanger in Tank No. 1 was converted to utilize cogen HWH. Pump (P-5) circulates cogen HWH supply water to the existing heat exchanger (HX) and temperature in the tank is controlled via a 3-way thermostatic mixing valve. Existing Primary DHW Storage Tank No.1 converted to preheat DHW Cogen HWH Return Cogen HWH Supply HX HX Left: Existing primary DHW Storage Tank No. 1, heat exchanger (converted to utilize HWH), circulation pump (P-5), and thermostatic 3-way mixing valve. HX P-5 Existing Secondary DHW Storage Tank No.2 Right: View of existing Primary DHW Storage Tank No.1 & Secondary Storage Tank No.2, circulation pump (P-5), and mixing valve. File: PI-93009 - Hospital Cogen 07.DOC 93009 - Page 7 of 14
POWER GENySYS Burlington, Ontario. Remote Heat Dump Radiator Remote Heat Dump Radiator: The engine-generator set requires adequate cooling of the low and high temperature cooling circuits in order to maintain proper operation. This is accomplished via a remote roof mounted split coil heat dump radiator. 2 ½ Cogen HTCC Piping (Glycol/Water) 1 Expansion Lines (Glycol/Water) 1 ½ Cogen LTCC Piping (Glycol/Water) Electrical Conduits (Power & Controls) Outlet Damper Heat recovery was not incorporated for the genset aftercooler circuit; the Low Temperature Cooling Circuit (LTCC). All thermal energy from the LTCC is rejected to the LTCC coil (outer coil) of the heat dump radiator. Heat recovery was incorporated for the genset oil cooler and jacket water circuits; the High Temperature Cooling Circuit (HTCC). Thermal energy not utilized within the building hot water heating system is diverted to the HTCC coil (inner coil) of the heat dump radiator where it is rejected. Above: View of the remote heat dump radiator, and connecting piping / conduits. Remote Heat Dump Radiator Discharge Silencer FAN Inlet Silencer Remote Heat Dump Radiator Above: Roof mounted remote Heat Dump Radiator & piping to cogen room. Above: Heat dump radiator - coils, expansion tanks, variable speed fan & silencers. Expansion Tanks Power disconnect box Expansion Tank Radiator Cooling Coils: Outer - LTCC Inner - HTCC Expansion Tank Low Level Alarm Switch 1 Expansion Lines 1 ½ Cogen LTCC Piping (Glycol/Water) 2 ½ Cogen HTCC Piping (Glycol/Water) Inner Coil HTCC Outer Coil LTCC Above: Heat dump radiator - coils, expansion tanks, variable speed fan & silencers. Above: Piping & conduits to radiator. Above: Expansion Tank & Low Level Alarm. File: PI-93009 - Hospital Cogen 08.DOC 93009 - Page 8 of 14
POWER GENySYS - Burlington, Ontario. Drawing M-1: Mechanical Schematic: Mechanical Schematic of Cogeneration System interconnection to existing Heating Plant. File: PI-93009 - Hospital Cogen 09.DOC 93009 - Page 9 of 15
POWER GENySYS - Burlington, Ontario. Drawing M-3: Mechanical Demolition and Layout: Mechanical Demolition Work and Layout of new System. File: PI-93009 - Hospital Cogen 10.DOC 93009 - Page 10 of 15
POWER GENySYS - Burlington, Ontario. Drawing M-6: Mechanical North Elevation: Mechanical - North Wall Elevation. File: PI-93009 - Hospital Cogen 11.DOC 93009 - Page 11 of 15
POWER GENySYS - Burlington, Ontario. Drawing M-7: Mechanical Sections: Mechanical Sections Inside New. File: PI-93009 - Hospital Cogen 12.DOC 93009 - Page 12 of 15
POWER GENySYS - Burlington, Ontario. Drawing M-8: Roof Mounted Heat Dump Radiator Layout and Details: Mechanical Layout of Roof Mounted Remote Heat Dump Radiator. File: PI-93009 - Hospital Cogen 13.DOC 93009 - Page 13 of 15
POWER GENySYS - Burlington, Ontario. Drawing P&I-1: Remote Monitoring P&I: Process and Instrumentation Drawing for Remote Monitoring / Datalogging System. File: PI-93009 - Hospital Cogen 14.DOC 93009 - Page 14 of 15
POWER GENySYS - Burlington, Ontario. Drawing E-3: Electrical Layout Plan: Electrical Layout Drawing. File: PI-93009 - Hospital Cogen 15.DOC 93009 - Page 15 of 15